Thermoplastic Non-Woven Textile Elements

ABSTRACT

A non-woven textile may be formed from a plurality of thermoplastic polymer filaments. The non-woven textile may have a first region and a second region, with the filaments of the first region being fused to a greater degree than the filaments of the second region. A variety of products, including apparel (e.g., shirts, pants, footwear), may incorporate the non-woven textile. In some of these products, the non-woven textile may be joined with another textile element to form a seam. More particularly, an edge area of the non-woven textile may be heatbonded with an edge area of the other textile element at the seam. In other products, the non-woven textile may be joined with another component, whether a textile or a non-textile.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a divisional of and claims priority under 35 U.S.C.121 to U.S. patent application Ser. No. 12/367,274, which was filed inthe U.S. Patent and Trademark Office on 6 Feb. 2009 and entitledThermoplastic Non-Woven Textile Elements, such prior U.S. patentapplication being entirely incorporated herein by reference.

BACKGROUND

A variety of products are at least partially formed from textiles. Asexamples, articles of apparel (e.g., shirts, pants, socks, jackets,undergarments, footwear), containers (e.g., backpacks, bags), andupholstery for furniture (e.g., chairs, couches, car seats) are oftenformed from various textile elements that are joined through stitchingor adhesive bonding. Textiles may also be utilized in bed coverings(e.g., sheets, blankets), table coverings, towels, flags, tents, sails,and parachutes. Textiles utilized for industrial purposes are commonlyreferred to as technical textiles and may include structures forautomotive and aerospace applications, filter materials, medicaltextiles (e.g. bandages, swabs, implants), geotextiles for reinforcingembankments, agrotextiles for crop protection, and industrial apparelthat protects or insulates against heat and radiation. Accordingly,textiles may be incorporated into a variety of products for bothpersonal and industrial purposes.

Textiles may be defined as any manufacture from fibers, filaments, oryarns having a generally two-dimensional structure (i.e., a length and awidth that are substantially greater than a thickness). In general,textiles may be classified as mechanically-manipulated textiles ornon-woven textiles. Mechanically-manipulated textiles are often formedby weaving or interlooping (e.g., knitting) a yarn or a plurality ofyarns, usually through a mechanical process involving looms or knittingmachines. Non-woven textiles are webs or mats of filaments that arebonded, fused, interlocked, or otherwise joined. As an example, anon-woven textile may be formed by randomly depositing a plurality ofpolymer filaments upon a surface, such as a moving conveyor. Variousembossing or calendaring processes may also be utilized to ensure thatthe non-woven textile has a substantially constant thickness, imparttexture to one or both surfaces of the non-woven textile, or furtherbond or fuse filaments within the non-woven textile to each other.Whereas spunbonded non-woven textiles are formed from filaments having across-sectional thickness of 10 to 100 microns, meltblown non-woventextiles are formed from filaments having a cross-sectional thickness ofless than 10 microns.

Although some products are formed from one type of textile, manyproducts may also be formed from two or more types of textiles in orderto impart different properties to different areas. As an example,shoulder and elbow areas of a shirt may be formed from a textile thatimparts durability (e.g., abrasion-resistance) and stretch-resistance,whereas other areas may be formed from a textile that impartsbreathability, comfort, stretch, and moisture-absorption. As anotherexample, an upper for an article of footwear may have a structure thatincludes numerous layers formed from various types of textiles and othermaterials (e.g., polymer foam, leather, synthetic leather), and some ofthe layers may also have areas formed from different types of textilesto impart different properties. As yet another example, straps of abackpack may be formed from non-stretch textile elements, lower areas ofa backpack may be formed from durable and water-resistant textileelements, and a remainder of the backpack may be formed from comfortableand compliant textile elements. Accordingly, many products mayincorporate various types of textiles in order to impart differentproperties to different portions of the products.

In order to impart the different properties to different areas of aproduct, textile elements formed from the materials must be cut todesired shapes and then joined together, usually with stitching oradhesive bonding. As the number and types of textile elementsincorporated into a product increases, the time and expense associatedwith transporting, stocking, cutting, and joining the textile elementsmay also increase. Waste material from cutting and stitching processesalso accumulates to a greater degree as the number and types of textileelements incorporated into a product increases. Moreover, products witha greater number of textile elements and other materials may be moredifficult to recycle than products formed from few elements andmaterials. By decreasing the number of elements and materials utilizedin a product, therefore, waste may be decreased while increasing themanufacturing efficiency and recyclability.

SUMMARY

A non-woven textile and products incorporating the non-woven textile aredisclosed below. The non-woven textile may be formed from a plurality offilaments that are at least partially formed from a thermoplasticpolymer material. In some configurations of the non-woven textile, thefilaments or the thermoplastic polymer material may be elastomeric ormay stretch at least one-hundred percent prior to tensile failure.

The non-woven textile may have a first region and a second region, withthe filaments of the first region being fused to a greater degree thanthe filaments of the second region. Depending upon the degree of fusingin the first region, the thermoplastic polymer material from thefilaments may remain filamentous, become non-filamentous, or take anintermediate form that is partially filamentous and partiallynon-filamentous. Fusing within the first region may alter propertiessuch as permeability, durability, and stretch-resistance.

A variety of products, including apparel (e.g., shirts, pants,footwear), may incorporate the non-woven textile. In some of theseproducts, the non-woven textile may be joined with another textileelement or component to form a seam. More particularly, an edge area ofthe non-woven textile may be heatbonded with an edge area of the othertextile element or component at the seam. In other products, a surfacethe non-woven textile may be joined with another textile element orcomponent (e.g., a polymer sheet, a polymer foam layer, or variousstrands) to form a composite element.

The advantages and features of novelty characterizing aspects of theinvention are pointed out with particularity in the appended claims. Togain an improved understanding of the advantages and features ofnovelty, however, reference may be made to the following descriptivematter and accompanying figures that describe and illustrate variousconfigurations and concepts related to the invention.

FIGURE DESCRIPTIONS

The foregoing Summary and the following Detailed Description will bebetter understood when read in conjunction with the accompanyingfigures.

FIG. 1 is a perspective view of a non-woven textile.

FIG. 2 is a cross-sectional view of the non-woven textile, as defined bysection line 2-2 in FIG. 1.

FIG. 3 is a perspective view of the non-woven textile with a pluralityof fused regions.

FIGS. 4A-4C are cross-sectional views, as defined by section line 4-4 inFIG. 3, depicting different configurations of the fused regions in thenon-woven textile.

FIGS. 5A-5H are perspective views of further configurations of the fusedregions in the non-woven textile.

FIGS. 6A-6F are cross-sectional views corresponding with FIGS. 4A-4C anddepicting further configurations of the fused regions in the non-woventextile.

FIGS. 7A-7C are perspective views of a first process for forming thefused regions in the non-woven textile.

FIGS. 8A-8C are perspective views of a second process for forming thefused regions in the non-woven textile.

FIG. 9 is a perspective view of a third process for forming the fusedregions in the non-woven textile.

FIG. 10 is a perspective view of a first composite element that includesthe non-woven textile.

FIG. 11 is a cross-sectional view of the first composite element, asdefined by section line 11-11 in FIG. 10.

FIGS. 12A-12C are perspective views of a process for forming the firstcomposite element.

FIG. 13 is a schematic perspective view of a another process for formingthe first composite element.

FIG. 14 is a perspective view of a second composite element thatincludes the non-woven textile.

FIG. 15 is a cross-sectional view of the second composite element, asdefined by section line 15-15 in FIG. 14.

FIG. 16 is a perspective view of a third composite element that includesthe non-woven.

FIG. 17 is a cross-sectional view of the third composite element, asdefined by section line 17-17 in FIG. 16.

FIGS. 18A-18C are perspective views of further configurations of thethird composite element.

FIG. 19 is a perspective view of a fourth composite element thatincludes the non-woven textile.

FIG. 20 is a cross-sectional view of the fourth composite element, asdefined by section line 20-20 in FIG. 19.

FIG. 21 is a perspective view of a fifth composite element that includesthe non-woven textile.

FIG. 22 is a cross-sectional view of the fifth composite element, asdefined by section line 22-22 in FIG. 21.

FIGS. 23A-23F are perspective views of further configurations of thefifth composite element.

FIG. 24 is a perspective view of two elements of the non-woven textilejoined with a first seam configuration.

FIG. 25 is a cross-sectional view of the first seam configuration, asdefined by section line 25-25 in FIG. 24.

FIGS. 26A-26D are side elevational views of a process for forming thefirst seam configuration.

FIG. 27 is a perspective view of another process for forming the firstseam configuration.

FIGS. 28A and 28B are perspective views of elements of the non-woventextile joined with other elements to form the first seam configuration.

FIGS. 29A-29C are cross-sectional views corresponding with FIG. 25 anddepicting further examples of the first seam configuration.

FIG. 30 is a perspective view of two elements of the non-woven textilejoined with a second seam configuration.

FIG. 31 is a cross-sectional view of the second seam configuration, asdefined by section line 31-31 in FIG. 30.

FIGS. 32A-32C are side elevational views of a process for forming thesecond seam configuration.

FIG. 33 is a perspective view of another process for forming the secondseam configuration.

FIGS. 34A-34C are cross-sectional views corresponding with FIG. 31 anddepicting further configurations of the second seam configuration.

FIGS. 35A-35H are front elevational views of various configurations of ashirt that includes the non-woven textile.

FIGS. 36A-36H are cross-sectional views of the configurations of theshirt, as respectively defined by section lines 36A-36A through 36H-36Hin FIGS. 35A-35H.

FIGS. 37A-37C are front elevational views of various configurations of apair of pants that includes the non-woven textile.

FIG. 38 is a cross-sectional view of the pair of pants, as defined bysection line 38-38 in FIG. 33A.

FIGS. 39A-39G are side elevational views of various configurations of anarticle of footwear that includes the non-woven textile.

FIGS. 40A-40D are cross-sectional views of the configurations of thearticle of footwear, as respectively defined by section lines 40A-40Athrough 40D-40D in FIGS. 39A-39D.

FIG. 41 is a perspective view of a lace loop for the article of footwearthat includes the non-woven textile.

FIGS. 42A-42C are perspective views of three-dimensional configurationsof the non-woven textile.

FIGS. 43A-43C are perspective views of a process for forming thethree-dimensional configurations of the non-woven textile.

FIGS. 44A-44D are perspective views of textured configurations of thenon-woven textile.

FIGS. 45A-45C are perspective views of a process for forming thetextured configurations of the non-woven textile.

FIGS. 46A-46F are perspective views of stitched configurations of thenon-woven textile.

FIG. 47 is a perspective view of an element of tape that includes thenon-woven textile.

FIG. 48 is a cross-sectional view of the tape, as defined by sectionline 48-48 in FIG. 47.

FIGS. 49A-49C are perspective views of additional configurations of theelement of tape.

FIG. 50 is a schematic view of a recycling process.

DETAILED DESCRIPTION

The following discussion and accompanying figures disclose a non-woventextile 100 and various products incorporating non-woven textile 100.Although non-woven textile 100 is disclosed below as being incorporatedinto various articles of apparel (e.g., shirts, pants, footwear) forpurposes of example, non-woven textile 100 may also be incorporated intoa variety of other products. For example, non-woven textile 100 may beutilized in other types of apparel, containers, and upholstery forfurniture. Non-woven textile 100 may also be utilized in bed coverings,table coverings, towels, flags, tents, sails, and parachutes. Variousconfigurations of non-woven textile 100 may also be utilized forindustrial purposes, as in automotive and aerospace applications, filtermaterials, medical textiles, geotextiles, agrotextiles, and industrialapparel. Accordingly, non-woven textile 100 may be utilized in a varietyof products for both personal and industrial purposes.

I—NON-WOVEN TEXTILE CONFIGURATION

Non-woven textile 100 is depicted in FIGS. 1 and 2 as having a firstsurface 101 and an opposite second surface 102. Non-woven textile 100 isprimarily formed from a plurality of filaments 103 that include athermoplastic polymer material. Filaments 103 are distributed randomlythroughout non-woven textile 100 and are bonded, fused, interlocked, orotherwise joined to form a structure with a relatively constantthickness (i.e., distance between surfaces 101 and 102). An individualfilament 103 may be located on first surface 101, on second surface 102,between surfaces 101 and 102, or on both of surfaces 101 and 102.Depending upon the manner in which non-woven textile 100 is formed,multiple portions of an individual filament 103 may be located on firstsurface 101, different portions of the individual filament 103 may belocated on second surface 102, and other portions of the individualfilament 103 may be located between surfaces 101 and 102. In order toimpart an interlocking structure, the various filaments 103 may wraparound each other, extend over and under each other, and pass throughvarious areas of non-woven textile 100. In areas where two or morefilaments 103 contact each other, the thermoplastic polymer materialforming filaments 103 may be bonded or fused to join filaments 103 toeach other. Accordingly, filaments 103 are effectively joined to eachother in a variety of ways to form a cohesive structure within non-woventextile 100.

Fibers are often defined, in textile terminology, as having a relativelyshort length that ranges from one millimeter to a few centimeters ormore, whereas filaments are often defined as having a longer length thanfibers or even an indeterminate length. As utilized within the presentdocument, the term “filament” or variants thereof is defined asencompassing lengths of both fibers and filaments from the textileterminology definitions. Accordingly, filaments 103 or other filamentsreferred to herein may generally have any length. As an example,therefore, filaments 103 may have a length that ranges from onemillimeter to hundreds of meters or more.

Filaments 103 include a thermoplastic polymer material. In general, athermoplastic polymer material melts when heated and returns to a solidstate when cooled. More particularly, the thermoplastic polymer materialtransitions from a solid state to a softened or liquid state whensubjected to sufficient heat, and then the thermoplastic polymermaterial transitions from the softened or liquid state to the solidstate when sufficiently cooled. As such, the thermoplastic polymermaterial may be melted, molded, cooled, re-melted, re-molded, and cooledagain through multiple cycles. Thermoplastic polymer materials may alsobe welded or heatbonded, as described in greater detail below, to othertextile elements, plates, sheets, polymer foam elements, thermoplasticpolymer elements, thermoset polymer elements, or a variety of otherelements formed from various materials. In contrast with thermoplasticpolymer materials, many thermoset polymer materials do not melt whenheated, simply burning instead. Although a wide range of thermoplasticpolymer materials may be utilized for filaments 103, examples of somesuitable thermoplastic polymer materials include thermoplasticpolyurethane, polyamide, polyester, polypropylene, and polyolefin.Although any of the thermoplastic polymer materials mentioned above maybe utilized for non-woven textile 100, an advantage to utilizingthermoplastic polyurethane relates to heatbonding and colorability. Incomparison with various other thermoplastic polymer materials (e.g.,polyolefin), thermoplastic polyurethane is relatively easy to bond withother elements, as discussed in greater detail below, and colorants maybe added to thermoplastic polyurethane through various conventionalprocesses.

Although each of filaments 103 may be entirely formed from a singlethermoplastic polymer material, individual filaments 103 may also be atleast partially formed from multiple polymer materials. As an example,an individual filament 103 may have a sheath-core configuration, whereinan exterior sheath of the individual filament 103 is formed from a firsttype of thermoplastic polymer material, and an interior core of theindividual filament 103 is formed from a second type of thermoplasticpolymer material. As a similar example, an individual filament 103 mayhave a bi-component configuration, wherein one half of the individualfilament 103 is formed from a first type of thermoplastic polymermaterial, and an opposite half of the individual filament 103 is formedfrom a second type of thermoplastic polymer material. In someconfigurations, an individual filament 103 may be formed from both athermoplastic polymer material and a thermoset polymer material witheither of the sheath-core or bi-component arrangements. Although all offilaments 103 may be entirely formed from a single thermoplastic polymermaterial, filaments 103 may also be formed from multiple polymermaterials. As an example, some of filaments 103 may be formed from afirst type of thermoplastic polymer material, whereas other filaments103 may be formed from a second type of thermoplastic polymer material.As a similar example, some of filaments 103 may be formed from athermoplastic polymer material, whereas other filaments 103 may beformed from a thermoset polymer material. Accordingly, each filaments103, portions of filaments 103, or at least some of filaments 103 may beformed from one or more thermoplastic polymer materials.

The thermoplastic polymer material or other materials utilized fornon-woven textile 100 (i.e., filaments 103) may be selected to havevarious stretch properties, and the materials may be consideredelastomeric. Depending upon the specific product that non-woven textile100 will be incorporated into, non-woven textile 100 or filaments 103may stretch between ten percent to more than eight-hundred percent priorto tensile failure. For many articles of apparel, in which stretch is anadvantageous property, non-woven textile 100 or filaments 103 maystretch at least one-hundred percent prior to tensile failure. As arelated matter, thermoplastic polymer material or other materialsutilized for non-woven textile 100 (i.e., filaments 103) may be selectedto have various recovery properties. That is, non-woven textile 100 maybe formed to return to an original shape after being stretched, ornon-woven textile 100 may be formed to remain in an elongated orstretched shape after being stretched. Many products that incorporatenon-woven textile 100, such as articles of apparel, may benefit fromproperties that allow non-woven textile 100 to return or otherwiserecover to an original shape after being stretched by one-hundredpercent or more.

A variety of conventional processes may be utilized to manufacturenon-woven textile 100. In general, a manufacturing process for non-woventextile 100 includes (a) extruding or otherwise forming a plurality offilaments 103 from a thermoplastic polymer material, (b) collecting,laying, or otherwise depositing filaments 103 upon a surface, such as amoving conveyor, (c) joining filaments 103, and (d) imparting a desiredthickness through compressing or other processes. Because filaments 103may be relatively soft or partially melted when deposited upon thesurface, the polymer materials from filaments 103 that contact eachother may become bonded or fused together upon cooling.

Following the general manufacturing process discussed above, variouspost-processing operations may be performed on non-woven textile 100.For example, embossing or calendaring processes may be utilized toensure that non-woven textile 100 has a substantially constantthickness, impart texture to one or both of surfaces 101 and 102, orfurther bond or fuse filaments 103 to each other. Coatings may also beapplied to non-woven textile 100. Furthermore, hydrojet,hydroentangelment, needlepunching, or stitchbonding processes may alsobe utilized to modify properties of non-woven textile 100.

Non-woven textile 100 may be formed as a spunbonded or meltblownmaterial. Whereas spunbonded non-woven textiles are formed fromfilaments having a cross-sectional thickness of 10 to 100 microns,meltblown non-woven textiles are formed from filaments having across-sectional thickness of less than 10 microns. Non-woven textile 100may be either spunbonded, meltblown, or a combination of spunbonded andmeltblown. Moreover, non-woven textile 100 may be formed to havespunbonded and meltblown layers, or may also be formed such thatfilaments 103 are combinations of spunbonded and meltblown.

In addition to differences in the thickness of individual filaments 103,the overall thickness of non-woven textile 100 may vary significantly.With reference to the various figures, the thickness of non-woventextile 100 and other elements may be amplified or otherwise increasedto show details or other features associated with non-woven textile 100,thereby providing clarity in the figures. For many applications,however, a thickness of non-woven textile 100 may be in a range of 0.5millimeters to 10.0 millimeters, but may vary considerably beyond thisrange. For many articles of apparel, for example, a thickness of 1.0 to3.0 millimeters may be appropriate, although other thicknesses may beutilized. As discussed in greater detail below, regions of non-woventextile 100 may be formed such that the thermoplastic polymer materialforming filaments 103 is fused to a greater degree than in otherregions, and the thickness of non-woven textile 100 in the fused regionsmay be substantially reduced. Accordingly, the thickness of non-woventextile 100 may vary considerably.

II—FUSED REGIONS

Non-woven textile 100 is depicted as including various fused regions 104in FIG. 3. Fused regions 104 are portions of non-woven textile 100 thathave been subjected to heat in order to selectively change theproperties of those fused regions 104. Non-woven textile 100, or atleast the various filaments 103 forming non-woven textile 100, arediscussed above as including a thermoplastic polymer material. Whenexposed to sufficient heat, the thermoplastic polymer materialtransitions from a solid state to either a softened state or a liquidstate. When sufficiently cooled, the thermoplastic polymer material thentransitions back from the softened state or the liquid state to thesolid state. Non-woven textile 100 or regions of non-woven textile 100may, therefore, be exposed to heat in order to soften or melt thevarious filaments 103. As discussed in greater detail below, exposingvarious regions (i.e., fused regions 104) of non-woven textile 100 toheat may be utilized to selectively change the properties of thoseregions. Although discussed in terms of heat alone, pressure may also beutilized either alone or in combination with heat to form fused regions104, and pressure may be required in some configurations of non-woventextile 100 to form fused regions 104.

Fused regions 104 may exhibit various shapes, including a variety ofgeometrical shapes (e.g., circular, elliptical, triangular, square,rectangular) or a variety of non-defined, irregular, or otherwisenon-geometrical shapes. The positions of fused regions 104 may be spacedinward from edges of non-woven textile 100, located on one or more edgesof non-woven textile 100, or located at a corner of non-woven textile100. The shapes and positions of fused regions 104 may also be selectedto extend across portions of non-woven textile 100 or between two edgesof non-woven textile 100. Whereas the areas of some fused regions 104may be relatively small, the areas of other fused regions 104 may berelatively large. As described in greater detail below, two separateelements of non-woven textile 100 may be joined together, some fusedregions 104 may extend across a seam that joins the elements, or somefused regions may extend into areas where other components are bonded tonon-woven textile 100. Accordingly, the shapes, positions, sizes, andother aspects of fused regions 104 may vary significantly.

When exposed to sufficient heat, and possibly pressure, thethermoplastic polymer material of the various filaments 103 of non-woventextile 100 transitions from a solid state to either a softened state ora liquid state. Depending upon the degree to which filaments 103 changestate, the various filaments 103 within fused regions 104 may (a) remainin a filamentous configuration, (b) melt entirely into a liquid thatcools into a non-filamentous configuration, or (c) take an intermediateconfiguration wherein some filaments 103 or portions of individualfilaments 103 remain filamentous and other filaments 103 or portions ofindividual filaments 103 become non-filamentous. Accordingly, althoughfilaments 103 in fused regions 104 are generally fused to a greaterdegree than filaments 103 in other areas of non-woven textile 100, thedegree of fusing in fused regions 104 may vary significantly.

Differences between the degree to which filaments 103 may be fused infused regions 104 are depicted in FIGS. 4A-4C. Referring specifically toFIG. 4A, the various filaments 103 within fused region 104 remain in afilamentous configuration. That is, the thermoplastic polymer materialforming filaments 103 remains in the configuration of a filament andindividual filaments 103 remain identifiable. Referring specifically toFIG. 4B, the various filaments 103 within fused region 104 meltedentirely into a liquid that cools into a non-filamentous configuration.That is, the thermoplastic polymer material from filaments 103 meltedinto a non-filamentous state that effectively forms a solid polymersheet in fused region 104, with none of the individual filaments 103being identifiable. Referring specifically to FIG. 4C, the variousfilaments 103 remain in a partially-filamentous configuration. That is,some of the thermoplastic polymer material forming filaments 103 remainsin the configuration of a filament, and some of the thermoplasticpolymer material from filaments 103 melted into a non-filamentous statethat effectively forms a solid polymer sheet in fused region 104. Theconfiguration of the thermoplastic polymer material from filaments 103in fused regions 104 may, therefore, be filamentous, non-filamentous, orany combination or proportion of filamentous and non-filamentous.Accordingly, the degree of fusing in each of fused regions 104 may varyalong a spectrum that extends from filamentous on one end tonon-filamentous on an opposite end.

A variety of factors relating to the configuration of non-woven textile100 and the processes by which fused regions 104 are formed determinethe degree to which filaments 103 are fused within fused regions 104. Asexamples, factors that determine the degree of fusing include (a) theparticular thermoplastic polymer material forming filaments 103, (b) thetemperature that fused regions 104 are exposed to, (c) the pressure thatfused regions 104 are exposed to, and (d) the time at which fusedregions 104 are exposed to the elevated temperature and/or pressure. Byvarying these factors, the degree of fusing that results within fusedregions 104 may also be varied along the spectrum that extends fromfilamentous on one end to non-filamentous on an opposite end.

The configuration of fused regions 104 in FIG. 3 is intended to providean example of the manner in which the shapes, positions, sizes, andother aspects of fused regions 104 may vary. The configuration of fusedregions 104 may, however, vary significantly. Referring to FIG. 5A,non-woven textile 100 includes a plurality of fused regions 104 withgenerally linear and parallel configurations. Similarly, FIG. 5B depictsnon-woven textile 100 as including a plurality of fused regions 104 withgenerally curved and parallel configurations. Fused regions 104 may havea segmented configuration, as depicted in FIG. 5C. Non-woven textile 100may also have a plurality of fused regions 104 that exhibit theconfiguration of a repeating pattern of triangular shapes, as in FIG.5D, the configuration of a repeating pattern of circular shapes, as inFIG. 5E, or a repeating pattern of any other shape or a variety ofshapes. In some configurations of non-woven textile 100, as depicted inFIG. 5F, one fused region 104 may form a continuous area that definesdiscrete areas for the remainder of non-woven textile 100. Fused regions104 may also have a configuration wherein edges or corners contact eachother, as in the checkered pattern of FIG. 5G. Additionally, the shapesof the various fused regions 104 may have a non-geometrical or irregularshape, as in FIG. 5H. Accordingly, the shapes, positions, sizes, andother aspects of fused regions 104 may vary significantly.

The thickness of non-woven textile 100 may decrease in fused regions104. Referring to FIGS. 4A-4C, for example, non-woven textile 100exhibits less thickness in fused region 104 than in other areas. Asdiscussed above, fused regions 104 are areas where filaments 103 aregenerally fused to a greater degree than filaments 103 in other areas ofnon-woven textile 100. Additionally, non-woven textile 100 or theportions of non-woven textile 100 forming fused regions 104 may becompressed while forming fused regions 104. As a result, the thicknessof fused regions 104 may be decreased in comparison with other areas ofnon-woven textile 100. Referring again to FIGS. 4A-4C, surfaces 102 and103 both exhibit a squared or abrupt transition between fused regions104 and other areas of non-woven textile 100. Depending upon the mannerin which fused regions 104 are formed, however, surfaces 102 and 103 mayexhibit other configurations. As an example, only first surface 101 hasa squared transition to fused regions 104 in FIG. 6A. Although thedecrease in thickness of fused regions 104 may occur through a squaredor abrupt transition, a curved or more gradual transition may also beutilized, as depicted in FIGS. 6B and 6C. In other configurations, anangled transition between fused regions 104 and other areas of non-woventextile 100 may be formed, as in FIG. 6D. Although a decrease inthickness often occurs in fused regions 104, no decrease in thickness ora minimal decrease in thickness is also possible, as depicted in FIG.6E. Depending upon the materials utilized in non-woven textile 100 andthe manner in which fused regions 104 are formed, fused regions 104 mayactually swell or otherwise increase in thickness, as depicted in FIG.6F. In each of FIGS. 6A-6F, fused regions 104 are depicted as having anon-filamentous configuration, but may also have the filamentousconfiguration or the intermediate configuration discussed above.

Based upon the above discussion, non-woven textile 100 is formed from aplurality of filaments 103 that include a thermoplastic polymermaterial. Although filaments 103 are bonded, fused, interlocked, orotherwise joined throughout non-woven textile 100, fused regions 104 areareas where filaments 103 are generally fused to a greater degree thanfilaments 103 in other areas of non-woven textile 100. The shapes,positions, sizes, and other aspects of fused regions 104 may varysignificantly. In addition, the degree to which filaments 103 are fusedmay also vary significantly to be filamentous, non-filamentous, or anycombination or proportion of filamentous and non-filamentous.

III—PROPERTIES OF FUSED REGIONS

The properties of fused regions 104 may be different than the propertiesof other regions of non-woven textile 100. Additionally, the propertiesof one of fused regions 104 may be different than the properties ofanother of fused regions 104. In manufacturing non-woven textile 100 andforming fused regions 104, specific properties may be applied to thevarious areas of non-woven textile 100. More particularly, the shapes offused regions 104, positions of fused regions 104, sizes of fusedregions 104, degree to which filaments 103 are fused within fusedregions 104, and other aspects of non-woven textile 100 may be varied toimpart specific properties to specific areas of non-woven textile 100.Accordingly, non-woven textile 100 may be engineered, designed, orotherwise structured to have particular properties in different areas.

Examples of properties that may be varied through the addition or theconfiguration of fused regions 104 include permeability, durability, andstretch-resistance. By forming one of fused regions 104 in a particulararea of non-woven textile 100, the permeability of that area generallydecreases, whereas both durability and stretch-resistance generallyincreases. As discussed in greater detail below, the degree to whichfilaments 103 are fused to each other has a significant effect upon thechange in permeability, durability, and stretch-resistance. Otherfactors that may affect permeability, durability, and stretch-resistanceinclude the shapes, positions, and sizes of fused regions 104, as wellas the specific thermoplastic polymer material forming filaments 103.

Permeability generally relates to ability of air, water, and otherfluids (whether gaseous or liquid) to pass through or otherwise permeatenon-woven textile 100. Depending upon the degree to which filaments 103are fused to each other, the permeability may vary significantly. Ingeneral, the permeability is highest in areas of non-woven textile 100where filaments 103 are fused the least, and the permeability is lowestin areas of non-woven textile 100 where filaments 103 are fused themost. As such, the permeability may vary along a spectrum depending uponthe degree to which filaments 103 are fused to each other. Areas ofnon-woven textile 100 that are separate from fused regions 104 (i.e.,non-fused areas of non-woven textile 100) generally exhibit a relativelyhigh permeability. Fused regions 104 where a majority of filaments 103remain in the filamentous configuration also exhibit a relatively highpermeability, but the permeability is generally less than in areasseparate from fused regions 104. Fused regions 104 where filaments 103are in both a filamentous and non-filamentous configuration have alesser permeability. Finally, areas where a majority or all of thethermoplastic polymer material from filaments 103 exhibits anon-filamentous configuration may have a relatively small permeabilityor even no permeability.

Durability generally relates to the ability of non-woven textile 100 toremain intact, cohesive, or otherwise undamaged, and may includeresistances to wear, abrasion, and degradation from chemicals and light.Depending upon the degree to which filaments 103 are fused to eachother, the durability may vary significantly. In general, the durabilityis lowest in areas of non-woven textile 100 where filaments 103 arefused the least, and the durability is highest in areas of non-woventextile 100 where filaments 103 are fused the most. As such, thedurability may vary along a spectrum depending upon the degree to whichfilaments 103 are fused to each other. Areas of non-woven textile 100that are separate from fused regions 104 generally exhibit a relativelylow durability. Fused regions 104 where a majority of filaments 103remain in the filamentous configuration also exhibit a relatively lowdurability, but the durability is generally more than in areas separatefrom fused regions 104. Fused regions 104 where filaments 103 are inboth a filamentous and non-filamentous configuration have a greaterdurability. Finally, areas where a majority or all of the thermoplasticpolymer material from filaments 103 exhibits a non-filamentousconfiguration may have a relatively high durability. Other factors thatmay affect the general durability of fused regions 104 and other areasof non-woven textile 100 include the initial thickness and density ofnon-woven textile 100, the type of polymer material forming filaments103, and the hardness of the polymer material forming filaments 103.

Stretch-resistance generally relates to the ability of non-woven textile100 to resist stretching when subjected to a textile force. As withpermeability and durability, the stretch-resistance of non-woven textile100 may vary significantly depending upon the degree to which filaments103 are fused to each other. As with durability, the stretch-resistanceis lowest in areas of non-woven textile 100 where filaments 103 arefused the least, and the stretch-resistance is highest in areas ofnon-woven textile 100 where filaments 103 are fused the most. As notedabove, the thermoplastic polymer material or other materials utilizedfor non-woven textile 100 (i.e., filaments 103) may be consideredelastomeric or may stretch at least one-hundred percent prior to tensilefailure. Although the stretch-resistance of non-woven textile 100 may begreater in areas of non-woven textile 100 where filaments 103 are fusedthe most, fused regions 104 may still be elastomeric or may stretch atleast one-hundred percent prior to tensile failure. Other factors thatmay affect the general stretch properties of fused regions 104 and otherareas of non-woven textile 100 include the initial thickness and densityof non-woven textile 100, the type of polymer material forming filaments103, and the hardness of the polymer material forming filaments 103.

As discussed in greater detail below, non-woven textile 100 may beincorporated into a variety of products, including various articles ofapparel (e.g., shirts, pants, footwear). Taking a shirt as an example,non-woven textile 100 may form a majority of the shirt, including atorso region and two arm regions. Given that moisture may accumulatewithin the shirt from perspiration, a majority of the shirt may beformed from portions of non-woven textile 100 that do not include fusedregions 104 in order to provide a relatively high permeability. Giventhat elbow areas of the shirt may be subjected to relatively highabrasion as the shirt is worn, some of fused regions 104 may be locatedin the elbow areas to impart greater durability. Additionally, giventhat the neck opening may be stretched as the shirt is put on anindividual and taken off the individual, one of fused regions 104 may belocated around the neck opening to impart greater stretch-resistance.Accordingly, one material (i.e., non-woven textile 100) may be usedthroughout the shirt, but by fusing different areas to differentdegrees, the properties may be advantageously-varied in different areasof the shirt.

The above discussion focused primarily on the properties ofpermeability, durability, and stretch-resistance. A variety of otherproperties may also be varied through the addition or the configurationof fused regions 104. For example, the overall density of non-woventextile 100 may be increased as the degree of fusing of filaments 103increases. The transparency of non-woven textile 100 may also beincreased as the degree of fusing of filaments 103 increases. Dependingupon various factors, the darkness of a color of non-woven textile 100may also increase as the degree of fusing of filaments 103 increases.Although somewhat discussed above, the overall thickness of non-woventextile 100 may decrease as the degree of fusing of filaments 103increases. The degree to which non-woven textile 100 recovers afterbeing stretched, the overall flexibility of non-woven textile 100, andresistance to various modes of failure may also vary depending upon thedegree of fusing of filaments 100. Accordingly, a variety of propertiesmay be varied by forming fused regions 104.

IV—FORMATION OF FUSED REGIONS

A variety of processes may be utilized to form fused regions 104.Referring to FIGS. 7A-7C, an example of a method is depicted asinvolving a first plate 111 and a second plate 112, which may be platensof a press. Initially, non-woven textile 100 and an insulating element113 are located between plates 111 and 112, as depicted in FIG. 7A.Insulating element 113 has apertures 114 or other absent areas thatcorrespond with fused regions 104. That is, insulating element 113exposes areas of non-woven textile 100 corresponding with fused regions104, while covering other areas of non-woven textile 100.

Plates 111 and 112 then translate or otherwise move toward each other inorder to compress or induce contact between non-woven textile 100 andinsulating element 113, as depicted in FIG. 7B. In order to form fusedregions 104, heat is applied to areas of non-woven textile 100corresponding with fused regions 104, but a lesser heat or no heat isapplied to other areas of non-woven textile 100 due to the presence ofinsulating element 113. That is, the temperature of the various areas ofnon-woven textile 100 corresponding with fused regions 104 is elevatedwithout significantly elevating the temperature of other areas. In thisexample method, first plate 111 is heated so as to elevate thetemperature of non-woven textile 100 through conduction. Some areas ofnon-woven textile 100 are insulated, however, by the presence ofinsulating element 113. Only the areas of non-woven textile 100 that areexposed through apertures 114 are, therefore, exposed to the heat so asto soften or melt the thermoplastic polymer material within filaments103. The material utilized for insulating element 113 may vary toinclude metal plates, paper sheets, polymer layers, foam layers, or avariety of other materials (e.g., with low thermal conductivity) thatwill limit the heat transferred to non-woven textile 100 from firstplate 111. In some processes, insulating element 113 may be an integralportion of or otherwise incorporated into first plate 111.

Upon separating plates 111 and 112, as depicted in FIG. 7C, non-woventextile 100 and insulating element 113 are separated from each other.Whereas areas of non-woven textile 100 that were exposed by apertures114 in insulating element 113 form fused regions 104, areas covered orotherwise protected by insulating element 113 remain substantiallyunaffected. In some methods, insulating element 113 may be structured toallow some of fused regions 104 to experience greater temperatures thanother fused regions 104, thereby fusing the thermoplastic polymermaterial of filaments 103 more in some of fused regions 104 than in theother fused regions 104. That is, the configuration of insulatingelement 113 may be structured to heat fused regions 104 to differenttemperatures in order to impart different properties to the variousfused regions 104.

Various methods may be utilized to apply heat to specific areas ofnon-woven textile 100 and form fused regions 104. As noted above, firstplate 111 may be heated so as to elevate the temperature of non-woventextile 100 through conduction. In some processes, both plates 111 and112 may be heated, and two insulating elements 113 may be located onopposite sides of non-woven textile 100. Although heat may be appliedthrough conduction, radio frequency heating may also be used, in whichcase insulating element 113 may prevent the passage of specificwavelengths of electromagnetic radiation. In processes where chemicalheating is utilized, insulating element 113 may prevent chemicals fromcontacting areas of non-woven textile 100. In other processes whereradiant heat is utilized, insulating element 113 may be a reflectivematerial (i.e., metal foil) that prevents the radiant heat from raisingthe temperature of various areas of non-woven textile 100. A similarprocess involving a conducting element may also be utilized. Moreparticularly, the conducting element may be used to conduct heatdirectly to fused regions 104. Whereas insulating element 113 is absentin areas corresponding with fused regions 104, the conducting elementwould be present in fused regions 104 to conduct heat to those areas ofnon-woven textile 100.

An example of another process that may be utilized to form fused regions104 in non-woven textile 100 is depicted in FIGS. 8A-8C. Initially,non-woven textile 100 is placed adjacent to or upon second plate 112 oranother surface, as depicted in FIG. 8A. A heated die 115 having theshape of one of fused regions 104 then contacts and compresses non-woventextile 100, as depicted in FIG. 8B, to heat a defined area of non-woventextile 100. Upon removal of die 115, one of fused regions 104 isexposed. Additional dies having the general shapes of other fusedregions 104 may be utilized to form the remaining fused regions 104 in asimilar manner. An advantage to this process is that die 115 and each ofthe other dies may be heated to different temperatures, held in contactwith non-woven textile 100 for different periods of time, and compressedagainst non-woven textile 100 with different forces, thereby varying theresulting properties of the various fused regions 104.

An example of yet another process that may be utilized to form fusedregions 104 in non-woven textile 100 is depicted in FIG. 9. In thisprocess, non-woven textile 100 is placed upon second plate 112 oranother surface, and a laser apparatus 116 is utilized to heat specificareas of non-woven textile 100, thereby fusing the thermoplastic polymermaterial of filaments 103 and forming fused regions 104. By adjustingany or all of the power, focus, or velocity of laser apparatus 116, thedegree to which fused regions 104 are heated may be adjusted orotherwise varied. Moreover, different fused regions 104 may be heated todifferent temperatures to modify the degree to which filaments 103 arefused, thereby varying the resulting properties of the various fusedregions 104. An example of a suitable laser apparatus 116 is any of avariety of conventional CO₂ or Nd:YAG laser apparatuses.

V—COMPOSITE ELEMENTS

Non-woven textile 100 may be joined with various textiles, materials, orother components to form composite elements. By joining non-woventextile 100 with other components, properties of both non-woven textile100 and the other components are combined in the composite elements. Anexample of a composite element is depicted in FIGS. 10 and 11, in whicha component 120 is joined to non-woven textile 100 at second surface102. Although component 120 is depicted as having dimensions that aresimilar to dimensions of non-woven textile 100, component 120 may have alesser or greater length, a lesser or greater width, or a lesser orgreater thickness. If, for example, component 120 is a textile thatabsorbs water or wicks water away, then the combination of non-woventextile 100 and component 120 may be suitable for articles of apparelutilized during athletic activities where an individual wearing theapparel is likely to perspire. As another example, if component 120 is acompressible material, such as a polymer foam, then the combination ofnon-woven textile 100 and component 120 may be suitable for articles ofapparel where cushioning (i.e., attenuation of impact forces) isadvantageous, such as padding for athletic activities that may involvecontact or impact with other athletes or equipment. As a furtherexample, if component 120 is a plate or sheet, then the combination ofnon-woven textile 100 and component 120 may be suitable for articles ofapparel that impart protection from acute impacts. Accordingly, avariety of textiles, materials, or other components maybe joined with asurface of non-woven textile 100 to form composite elements withadditional properties.

The thermoplastic polymer material in filaments 103 may be utilized tosecure non-woven textile 100 to component 120 or other components. Asdiscussed above, a thermoplastic polymer material melts when heated andreturns to a solid state when cooled sufficiently. Based upon thisproperty of thermoplastic polymer materials, heatbonding processes maybe utilized to form a heatbond that joins portions of compositeelements, such as non-woven textile 100 and component 120. As utilizedherein, the term “heatbonding” or variants thereof is defined as asecuring technique between two elements that involves a softening ormelting of a thermoplastic polymer material within at least one of theelements such that the materials of the elements are secured to eachother when cooled. Similarly, the term “heatbond” or variants thereof isdefined as the bond, link, or structure that joins two elements througha process that involves a softening or melting of a thermoplasticpolymer material within at least one of the elements such that thematerials of the elements are secured to each other when cooled. Asexamples, heatbonding may involve (a) the melting or softening of twoelements incorporating thermoplastic polymer materials such that thethermoplastic polymer materials intermingle with each other (e.g.,diffuse across a boundary layer between the thermoplastic polymermaterials) and are secured together when cooled; (b) the melting orsoftening of a first textile element incorporating a thermoplasticpolymer material such that the thermoplastic polymer material extendsinto or infiltrates the structure of a second textile element (e.g.,extends around or bonds with filaments or fibers in the second textileelement) to secure the textile elements together when cooled; and (c)the melting or softening of a textile element incorporating athermoplastic polymer material such that the thermoplastic polymermaterial extends into or infiltrates crevices or cavities formed inanother element (e.g., polymer foam or sheet, plate, structural device)to secure the elements together when cooled. Heatbonding may occur whenonly one element includes a thermoplastic polymer material or when bothelements include thermoplastic polymer materials. Additionally,heatbonding does not generally involve the use of stitching oradhesives, but involves directly bonding elements to each other withheat. In some situations, however, stitching or adhesives may beutilized to supplement the heatbond or the joining of elements throughheatbonding. A needlepunching process may also be utilized to join theelements or supplement the heatbond.

Although a heatbonding process may be utilized to form a heatbond thatjoins non-woven textile 100 and component 120, the configuration of theheatbond at least partially depends upon the materials and structure ofcomponent 120. As a first example, if component 120 is at leastpartially formed from a thermoplastic polymer material, then thethermoplastic polymer materials of non-woven textile 100 and component120 may intermingle with each other to secure non-woven textile 100 andcomponent 120 together when cooled. If, however, the thermoplasticpolymer material of component 120 has a melting point that issignificantly higher than the thermoplastic polymer material ofnon-woven textile 100, then the thermoplastic polymer material ofnon-woven textile 100 may extend into the structure, crevices, orcavities of component 120 to secure the elements together when cooled.As a second example, component 120 may be formed from a textile thatdoes not include a thermoplastic polymer material, and the thermoplasticpolymer material of non-woven textile 100 may extend around or bond withfilaments in component 120 to secure the textile elements together whencooled. As a third example, component 120 may be a polymer foammaterial, polymer sheet, or plate that includes a thermoplastic polymermaterial, and the thermoplastic polymer materials of non-woven textile100 and component 120 may intermingle with each other to securenon-woven textile 100 and component 120 together when cooled. As afourth example, component 120 may be a polymer foam material, polymersheet, or plate that does not include a thermoplastic polymer material,and the thermoplastic polymer material of non-woven textile 100 mayextend into or infiltrate crevices or cavities within component 120 tosecure the elements together when cooled. Referring to FIG. 11, aplurality of heatbond elements 105 (e.g., the thermoplastic polymermaterial from one or both of non-woven textile 100 and component 120)are depicted as extending between non-woven textile 100 and component120 to join the elements together. Accordingly, a heatbond may beutilized to join non-woven textile 100 and component 120 even whencomponent 120 is formed from a diverse range of materials or has one ofa variety of structures.

A general manufacturing process for forming a composite element will nowbe discussed with reference to FIGS. 12A-12C. Initially, non-woventextile 100 and component 120 are located between first plate 111 andsecond plate 112, as depicted in FIG. 12A. Plates 111 and 112 thentranslate or otherwise move toward each other in order to compress orinduce contact between non-woven textile 100 and component 120, asdepicted in FIG. 12B. In order to form the heatbond and join non-woventextile 100 and component 120, heat is applied to non-woven textile 100and component 120. That is, the temperatures of non-woven textile 100and component 120 are elevated to cause softening or melting of thethermoplastic polymer material at the interface between non-woventextile 100 and component 120. Depending upon the materials of bothnon-woven textile 100 and component 120, as well as the overallconfiguration of component 120, only first plate 111 may be heated, onlysecond plate 112 may be heated, or both plates 111 and 112 may be heatedso as to elevate the temperatures of non-woven textile 100 and component120 through conduction. Upon separating plates 111 and 112, as depictedin FIG. 12C, the composite element formed from both non-woven textile100 and component 120 may be removed and permitted to cool.

The manufacturing process discussed relative to FIGS. 12A-12C generallyinvolves (a) forming non-woven textile 100 and component 120 separatelyand (b) subsequently joining non-woven textile 100 and component 120 toform the composite element. Referring to FIG. 13, a process whereinfilaments 103 are deposited directly onto component 120 during themanufacture of non-woven textile 100 is depicted. Initially, component120 is placed upon plate 112, which may also be a moving conveyor. Anextrusion nozzle 121 then extrudes or otherwise forms a plurality offilaments 103 from a thermoplastic polymer material. As filaments 103fall upon component 120, filaments 103 collect, lie, or otherwisedeposit upon a surface of component 120, thereby forming non-woventextile 100. Once cooled, non-woven textile 100 is effectively joined tocomponent 120, thereby forming the composite element. Accordingly,filaments 103 may be deposited directly upon component 120 during themanufacture of non-woven textile 100. As a similar manufacturingprocess, material (e.g., foam, molten polymer, a coating) may besprayed, deposited, or otherwise applied to a surface of non-woventextile 100 to form the composite element. Moreover, a composite elementthat includes two or more layers of non-woven textile 100 may be formedby repeatedly depositing layers of filaments 103. When each of thelayers of filaments 103 have different properties or are formed fromdifferent polymer materials, the resulting composite element may havethe combined properties of the various layers.

Although the general processes discussed above may be utilized to form acomposite element from non-woven textile 100 and component 120, othermethods may also be utilized. Rather than heating non-woven textile 100and component 120 through conduction, other methods that include radiofrequency heating or chemical heating may be utilized. In someprocesses, second surface 102 and a surface of component 120 may beheated through radiant heating prior to being compressed between plates111 and 112. An advantage of utilizing radiant heating to elevate thetemperature of only the surfaces forming the heatbond is that thethermoplastic polymer material within other portions of non-woventextile 100 and component 120 are not heated significantly. In someprocesses, stitching or adhesives may also be utilized between non-woventextile 100 and component 120 to supplement the heatbond.

Non-woven textile 100 is depicted in FIGS. 10-12C as having aconfiguration that does not include fused regions 104. In order toimpart varying properties to a composite element, fused regions 104 maybe formed in non-woven textile 100. In some processes fused regions 104may be formed prior to joining non-woven textile 100 with anothercomponent (e.g., component 120). In other processes, however, fusedregions 104 may be formed during the heatbonding process or followingthe heatbonding process. Accordingly, fused regions 104 may be formed atany stage of the various manufacturing process for composite elements.

VI—COMPOSITE ELEMENT CONFIGURATIONS

Concepts relating to the general structure of composite elements andprocesses for forming the composite elements were presented above. Asmore specific examples, the following discussion discloses variouscomposite element configurations, wherein non-woven textile 100 isjoined with each of a mechanically-manipulated textile 130, a sheet 140,a foam layer 150, and a plurality of strands 160.

An example of a composite element that includes non-woven textile 100and mechanically-manipulated textile 130 is depicted in FIGS. 14 and 15.Whereas non-woven textile 100 is formed from randomly-distributedfilaments 103, textile 130 is formed by mechanically-manipulating one ormore yarns 131 to form a woven or interlooped structure. Whenmanufactured with an interlooped structure, textile 130 may be formedthrough a variety of knitting processes, including flat knitting, widetube circular knitting, narrow tube circular knit jacquard, single knitcircular knit jacquard, double knit circular knit jacquard, warp knitjacquard, and double needle bar raschel knitting, for example.Accordingly, textile 130 may have a variety of configurations, andvarious weft-knitting and warp-knitting techniques may be utilized tomanufacture textile 130. Although yarns 131 of textile 130 may be atleast partially formed from a thermoplastic polymer material, manymechanically-manipulated textiles are formed from natural filaments(e.g., cotton, silk) or thermoset polymer materials. In order to form aheatbond between non-woven textile 100 and textile 130, thethermoplastic polymer material from non-woven textile 100 extends aroundor bonds with yarns 131 or extends into the structure of yarns 131 tosecure non-woven textile 100 and textile 130 together when cooled. Moreparticularly, various heatbond elements 105 are depicted in FIG. 15 asextending around or into yarns 131 to form the heatbond. A processsimilar to the process discussed above relative to FIGS. 12A-12C may beutilized to form the heatbond between non-woven textile 100 and textile130. That is, the heatbond between non-woven textile 100 and textile 130may be formed, for example, by compressing and heating the elementsbetween plates 111 and 112.

The combination of non-woven textile 100 and textile 130 may impart someadvantages over either of non-woven textile 100 and textile 130 alone.For example, textile 130 may exhibit one-directional stretch, whereinthe configuration of yarns 131 allows textile 130 to stretch in onedirection, but limits stretch in a perpendicular direction. Whennon-woven textile 100 and textile 130 are joined, the composite elementmay also exhibit a corresponding one-directional stretch. As anotherexample, the composite element may also be incorporated into variousarticles of apparel, with textile 130 being positioned to contact theskin of an individual wearing the apparel, and the materials selectedfor textile 130 and the structure of textile 130 may impart more comfortthan non-woven textile 100 alone. In addition to these advantages,various fused regions 104 may be formed in non-woven textile 100 toimpart different degrees of permeability, durability, andstretch-resistance to specific areas of the composite element.Accordingly, the composite element may have a configuration that impartsa combination of properties that neither non-woven textile 100 nortextile 130 may impart alone.

Another example of a composite element, which includes non-woven textile100 and sheet 140, is depicted in FIGS. 16 and 17. Sheet 140 may beformed from a sheet or plate of a polymer, suede, synthetic suede,metal, or wood material, for example, and may be either flexible orinflexible. In order to form a heatbond between non-woven textile 100and sheet 140, the thermoplastic polymer material of non-woven textile100 may extend into or infiltrate crevices or cavities within sheet 140to secure the elements together when cooled. In circumstances wheresheet 140 is formed from a thermoplastic polymer material, then thethermoplastic polymer materials of non-woven textile 100 and sheet 140may intermingle with each other (e.g., diffuse across a boundary layerbetween the thermoplastic polymer materials) to secure non-woven textile100 and sheet 140 together when cooled. A process similar to the processdiscussed above relative to FIGS. 12A-12C may be utilized to form theheatbond between non-woven textile 100 and sheet 140. As an alternative,stitching or adhesives may be utilized, as well as a needle punchingprocess to push filaments 103 into or through sheet 140 to joinnon-woven textile 100 and sheet 140 or to supplement the heatbond.

The combination of non-woven textile 100 and sheet 140 may be suitablefor articles of apparel that impart protection from acute impacts, forexample. A lack of stitching, rivets, or other elements joiningnon-woven textile 100 and sheet 140 forms a relatively smooth interface.When incorporated into an article of apparel, the lack ofdiscontinuities in the area joining non-woven textile 100 and sheet 140may impart comfort to the individual wearing the apparel. As anotherexample, edges of sheet 140 are depicted as being spaced inward fromedges of non-woven textile 100. When incorporating the composite elementinto a product, such as apparel, the edges of non-woven textile 100 maybe utilized to join the composite element to other textile elements orportions of the apparel. In addition to these advantages, various fusedregions 104 may be formed in non-woven textile 100 to impart differentdegrees of permeability, durability, and stretch-resistance to areas ofthe composite element.

Although sheet 140 is depicted as having a solid or otherwise continuousconfiguration, sheet 140 may also be absent in various areas of thecomposite element. Referring to FIG. 18A, sheet 140 has theconfiguration of various strips of material, that extend acrossnon-woven textile 100. A similar configuration is depicted in FIG. 18B,wherein sheet 140 has the configuration of a grid. In addition toimparting strength and tear-resistance to the composite element, thestrip and grid configurations of sheet 140 expose portions of non-woventextile 100, thereby allowing permeability in the exposed areas. In eachof FIGS. 16-18B, sheet 140 is depicted as having a thickness that iscomparable to the thickness of non-woven textile 100. In FIG. 18C,however, sheet 140 is depicted as having a thickness that issubstantially less than the thickness of non-woven textile 100. Evenwith a reduced thickness, sheet 140 may impart strength andtear-resistance, while allowing permeability.

A further example of a composite element that includes two layers ofnon-woven textile 100 and foam layer 150 is depicted in FIGS. 19 and 20.Foam layer 150 may be formed from a foamed polymer material that iseither thermoset or thermoplastic. In configurations where foam layer150 is formed from a thermoset polymer material, the thermoplasticpolymer material from the two layers of non-woven textile 100 may extendinto or infiltrate crevices or cavities on opposite sides of foam layer150 to form heatbonds and secure the elements together. Inconfigurations where foam layer 150 is formed from a thermoplasticpolymer material, the thermoplastic polymer materials of the two layersof non-woven textile 100 and foam layer 150 may intermingle with eachother to form heatbonds and secure the elements together.

A process similar to the process discussed above relative to FIGS.12A-12C may be utilized to form the heatbonds between the two layer ofnon-woven textile 100 and foam layer 150. More particularly, foam layer150 may be placed between the two layers of non-woven textile 100, andthese three elements may be located between plates 111 and 112. Uponcompressing and heating, heatbonds may form between the two layers ofnon-woven textile 100 and the opposite sides of foam layer 150.Additionally, the two layers of non-woven textile 100 may be heatbondedto each other around the perimeter of foam layer 150. That is, heatbondsmay also be utilized to join the two layers of non-woven textile 100 toeach other. In addition to foam layer 150, other intermediate elements(e.g., textile 130 or sheet 140) may be bonded between the two layers ofnon-woven textile 100. A needle punching process may also be utilized topush filaments 103 into or through foam layer 150 to join non-woventextile 100 and foam layer 150 or to supplement the heatbond, as well asstitching or adhesives.

The combination of the two layers of non-woven textile 100 and foamlayer 150 may be suitable for articles of apparel where cushioning(i.e., attenuation of impact forces) is advantageous, such as paddingfor athletic activities that may involve contact or impact with otherathletes or equipment. The lack of discontinuities in the area joiningthe layers of non-woven textile 100 and foam layer 150 may impartcomfort to the individual wearing the apparel. The edges of the twolayers of non-woven textile 100 may also be utilized to join thecomposite element to other textile elements or portions of the apparel.In addition to these advantages, various fused regions 104 may be formedin non-woven textile 100 to impart different degrees of permeability,durability, and stretch-resistance to the composite element.

An example of a composite element that includes non-woven textile 100and a plurality of strands 160 is depicted in FIGS. 21 and 22. Strands160 are secured to non-woven textile 100 and extend in a direction thatis substantially parallel to either of surfaces 101 and 102. Referringto the cross-section of FIG. 22, the positions of strands 160 relativeto surfaces 101 and 102 may vary significantly. More particularly,strands 160 may be located upon first surface 101, strands 160 may bepartially embedded within first surface 101, strands 160 may be recessedunder and adjacent to first surface 101, strands 160 may be spacedinward from first surface 101 and located between surfaces 101 and 102,or strands 160 may be adjacent to second surface 102. A heatbondingprocess may be utilized to secure strands 160 to non-woven textile 100.That is, thermoplastic polymer material of non-woven textile 100 may besoftened or melted to form a heatbond that joins strands 160 tonon-woven textile 100. Depending upon the degree to which thethermoplastic polymer material of non-woven textile 100 is softened ormelted, strands 160 may be positioned upon first surface 101 or locatedinward from first surface 101.

Strands 160 may be formed from any generally one-dimensional materialexhibiting a length that is substantially greater than a width and athickness. Depending upon the material utilized and the desiredproperties, strands 160 may be individual filaments, yarns that includea plurality of filaments, or threads that include a plurality of yarns.As discussed in greater detail below, suitable materials for strands 160include rayon, nylon, polyester, polyacrylic, silk, cotton, carbon,glass, aramids (e.g., para-aramid fibers and meta-aramid fibers), ultrahigh molecular weight polyethylene, and liquid crystal polymer, forexample. In some configurations, strands 160 may also be metal wires orcables.

In comparison with the thermoplastic polymer material forming non-woventextile 100, many of the materials noted above for strands 160 exhibitgreater tensile strength and stretch-resistance. That is, strands 160may be stronger than non-woven textile 100 and may exhibit less stretchthan non-woven textile 100 when subjected to a tensile force. Thecombination of non-woven textile 100 and strands 160 imparts a structurewherein the composite element may stretch in one direction and issubstantially stretch-resistant and has more strength in anotherdirection. Referring to FIG. 21, two perpendicular directions areidentified with arrows 161 and 162. When the composite element issubjected to a tensile force (i.e., stretched) in the direction of arrow161, non-woven textile 100 may stretch significantly. When the compositeelement is subjected to a tensile force (i.e., stretched) in thedirection of arrow 162, however, strands 160 resist the force and aremore stretch-resistant than non-woven textile 100. Accordingly, strands160 may be oriented to impart strength and stretch-resistance to thecomposite element in particular directions. Although strands 160 arediscussed herein as imparting stretch-resistance, strands 160 may beformed from materials that stretch significantly. Strands 160 may alsobe utilized to impart other properties to the composite element. Forexample, strands 160 may be electrically-conductive to allow thetransmission of power or data, or strands 160 may be located withinnon-woven textile 100 to impart a particular aesthetic.

Strands 160 are depicted as being substantially parallel to each otherin FIG. 21, and ends of strands 160 are depicted as being spaced inwardfrom edges of non-woven textile 100. In other composite elementconfigurations, strands 160 may be arranged in other orientations andmay extend entirely or only partially across non-woven textile 100.Referring to FIG. 23A, strands 160 are depicted as crossing each other.Given the angle that strands 160 are oriented relative to each other,strands 160 may only partially limit the stretch in the direction ofarrow 161, but the composite element may be substantiallystretch-resistant in the direction of arrow 162. A similar configurationis depicted in FIG. 23B, wherein strands 160 cross each other at rightangles. In this configuration, strands 160 may impart stretch-resistancein the directions of both arrows 161 and 162. That is, the compositeelement may be stretch-resistant in all directions due to theorientation of strands 160. As another matter, whereas ends of strands160 are spaced inward from edges of non-woven textile 100 in FIG. 23A,the ends of strands 160 extend to the edges of non-woven textile 100 inFIG. 23B. Strands 160 are depicted as having a wave-like or non-linearconfiguration in FIG. 23C. In this configuration, strands 160 may permitsome stretch in the direction of arrow 162. Once strands 160 straightendue to the stretch, however, then strands 160 may substantially resiststretch and provide strength in the direction of arrow 162. Anotherconfiguration is depicted in FIG. 23D, wherein strands 160 are arrangedin a non-parallel configuration to radiate outward.

In some configurations of the composite element, fused regions 104 maybe added to further affect the properties of the composite element.Referring to FIG. 23E, a single fused region 104 extends acrossnon-woven textile 100 in the direction of arrow 161. Given that fusedregions 104 may exhibit more stretch-resistance than other areas ofnon-woven textile 100, the fused region in FIG. 23E may impart somestretch-resistance in the direction of arrow 161, and strands 160 mayimpart stretch-resistance to the direction of arrow 162. In someconfigurations, fused regions may extend along strands 160 and in thedirection of arrow 162, as depicted in FIG. 23F. Accordingly, fusedregions 104 may be utilized with strands 160 to impart specificproperties to a composite element.

The material properties of strands 160 relate to the specific materialsthat are utilized within strands 160. Examples of material propertiesthat may be relevant in selecting specific materials for strands 160include tensile strength, tensile modulus, density, flexibility,tenacity, and durability. Each of the materials noted above as beingsuitable for strands 160 exhibit different combinations of materialproperties. Accordingly, the material properties for each of thesematerials may be compared in selecting particular materials for strands160. Tensile strength is a measure of resistance to breaking whensubjected to tensile (i.e., stretching) forces. That is, a material witha high tensile strength is less likely to break when subjected totensile forces than a material with a low tensile strength. Tensilemodulus is a measure of resistance to stretching when subjected totensile forces. That is, a material with a high tensile modulus is lesslikely to stretch when subjected to tensile forces than a material witha low tensile modulus. Density is a measure of mass per unit volume.That is, a particular volume of a material with a high density has moreweight than the same volume of a material with a low density.

Nylon has a relatively low tensile strength, a relatively low tensilemodulus, and an average density when compared to each of the othermaterials. Steel has an average tensile strength, a moderately hightensile modulus, and a relatively high density when compared to theother materials. While nylon is less dense than steel (i.e., lighterthan steel), nylon has a lesser strength and a greater propensity tostretch than steel. Conversely, while steel is stronger and exhibitsless stretch, steel is significantly more dense (i.e., heavier thannylon). Each of the engineering fibers (e.g., carbon fibers, aramidfibers, ultra high molecular weight polyethylene, and liquid crystalpolymer) exhibit tensile strengths and tensile moduli that arecomparable to steel. In addition, the engineering fibers exhibitdensities that are comparable to nylon. That is, the engineering fibershave relatively high tensile strengths and tensile moduli, but also haverelatively low densities. In general, each of the engineering fibershave a tensile strength greater than 0.60 gigapascals, a tensile modulusgreater than 50 gigapascals, and a density less than 2.0 grams percentimeter cubed.

In addition to material properties, the structural properties of variousconfigurations of strands 160 may be considered when selecting aparticular configuration for a composite element. The structuralproperties of strands 160 relate to the specific structure that isutilized to form strands 160. Examples of structural properties that maybe relevant in selecting specific configurations for strands 160 includedenier, number of plies, breaking force, twist, and number of individualfilaments, for example.

Based upon the above discussion, non-woven textile 100 may be heatbondedor otherwise joined (e.g., through stitching or adhesive bonding) to avariety of other components to form composite elements. An advantage ofjoining non-woven textile 100 to the other components is that thecomposite elements generally include combined properties from bothnon-woven textile 100 and the other components. As examples, compositeelements may be formed by joining non-woven textile 100 to any oftextile 130, sheet 140, foam layer 150, and strands 160.

VII—SEAM FORMATION

In order to incorporate non-woven textile 100 into a product, non-woventextile 100 is often joined with other elements of the product to form aseam. For example, non-woven textile 100 may be joined with othernon-woven textile elements, various mechanically-manipulated textileelements, or polymer sheets. Although stitching and adhesive bonding maybe utilized to join non-woven textile 100 to the other elements of theproduct, the seam may also be formed through a heatbonding process.

As an example of the manner in which non-woven textile 100 may be joinedto another element, FIGS. 24 and 25 depict a pair of elements ofnon-woven textile 100 that are joined to form a seam 106. That is, anedge area of one non-woven textile 100 is joined with an edge area ofthe other non-woven textile 100 at seam 106. More particularly, seam 106is formed by heatbonding first surface 101 of one non-woven textile 100with first surface 101 of the other non-woven textile 100. As with someconventional stitched seams, first surfaces 101 from each non-woventextile 100 are turned inward at seam 106 to face each other, and firstsurfaces 101 are joined to each other. In contrast with someconventional stitched seams, a heatbond is utilized to join firstsurfaces 101 from each non-woven textile 100 to each other. In someconfigurations, however, stitching or adhesive bonding may also beutilized to reinforce seam 106.

A general manufacturing process for forming seam 106 will now bediscussed with reference to FIGS. 26A-26D. Initially, the pair ofelements of non-woven textile 100 are located between a firstseam-forming die 117 and a second seam-forming die 118, as depicted inFIG. 26A. Seam-forming dies 117 and 118 then translate or otherwise movetoward each other in order to compress or induce contact between edgeareas of the pair of elements of non-woven textile 100, as depicted inFIG. 26B. In order to form the heatbond and join the edge areas of theelements of non-woven textile 100, seam-forming dies 117 and 118 applyheat to the edge areas. That is, seam-forming dies 117 and 118 elevatethe temperatures of the edge areas of the pair of elements of non-woventextile 100 to cause softening or melting of the thermoplastic polymermaterial at the interface between the edge areas. Upon separatingseam-forming dies 117 and 118, as depicted in FIG. 26C, seam 106 isformed between the edge areas of the pair of elements of non-woventextile 100. After being permitted to cool, the pair of elements ofnon-woven textile 100 may be unfolded, as depicted in FIG. 26D. Afterforming, seam 106 may also be trimmed to limit the degree to which theend areas of the pair of elements of non-woven textile 100 extenddownward at seam 106.

Although the general process discussed above may be utilized to formseam 106, other methods may also be utilized. Rather than heating theedge areas of elements of non-woven textile 100 through conduction,other methods that include radio frequency heating, chemical heating, orradiant heating may be utilized. In some processes, stitching oradhesives may also be utilized between the pair of elements of non-woventextile 100 to supplement the heatbond. As an alternate method, the pairof elements of non-woven textile 100 may be placed upon a surface, suchas second plate 112, and a heated roller 119 may form seam 106, asdepicted in FIG. 27.

As with the formation of fused regions 104, the formation of seam 106involves softening or melting the thermoplastic polymer material invarious filaments 103 that are located in the area of seam 106.Depending upon the degree to which filaments 103 change state, thevarious filaments 103 in the area of seam 106 may (a) remain in afilamentous configuration, (b) melt entirely into a liquid that coolsinto a non-filamentous configuration, or (c) take an intermediateconfiguration wherein some filaments 103 or portions of individualfilaments 103 remain filamentous and other filaments 103 or portions ofindividual filaments 103 become non-filamentous. Referring to FIG. 25,filaments 103 are depicted as remaining in the filamentous configurationin the area of seam 106, but may be melted into a non-filamentousconfiguration or may take the intermediate configuration. Accordingly,although filaments 103 in the area of seam 106 are generally fused to agreater degree than filaments 103 in other areas of non-woven textile100, the degree of fusing may vary significantly.

In forming seam 106 between the pair of elements of non-woven textile100, the thermoplastic polymer materials from the various filaments 103intermingle with each other and are secured together when cooled.Non-woven textile 100 may also be joined with other types of elements toform a similar seam 106. As a first example, non-woven textile 100 isdepicted as being joined with mechanically-manipulated textile 130 atseam 106 in FIG. 28A. Although yarns 131 of textile 130 may be at leastpartially formed from a thermoplastic polymer material, manymechanically-manipulated textiles are formed from natural filaments(e.g., cotton, silk) or thermoset polymer materials. In order to form aheatbond between non-woven textile 100 and textile 130 at seam 106, thethermoplastic polymer material from non-woven textile 100 extends aroundor bonds with yarns 131 or extends into the structure of yarns 131 tosecure the non-woven textile 100 and textile 130 together at seam 106when cooled. As a second example, non-woven textile 100 is depicted asbeing joined with sheet 140 at seam 106 in FIG. 28B. In someconfigurations, sheet 140 may be a flexible polymer sheet. In order toform a heatbond between non-woven textile 100 and sheet 140 at seam 106,the thermoplastic polymer material of non-woven textile 100 may extendinto or infiltrate crevices or cavities within sheet 140 to secure theelements together when cooled. In circumstances where sheet 140 isformed from a thermoplastic polymer material, then the thermoplasticpolymer materials of non-woven textile 100 and sheet 140 may interminglewith each other to secure non-woven textile 100 and sheet 140 togetherat seam 106 when cooled.

The thicknesses of elements of non-woven textile 100 are depicted asbeing substantially uniform, even in the areas of seam 106. Dependingupon the temperature and pressure used to form seam 106, theconfiguration of seam 106 may vary to include a variety of otherconfigurations. Referring to FIG. 29A, elements of non-woven textile 100exhibit reduced thicknesses in the areas of seam 106, and thethermoplastic polymer material of filaments 103 is depicted as being ina non-filamentous configuration. Seam 106 may also exhibit a pointedconfiguration, as depicted in FIG. 29B. The temperature and pressureused to form seam 106 may also impart a stepped structure, as depictedin FIG. 29C. Accordingly, the configuration of the pair of elements ofnon-woven textile 100 at seam 106 may vary significantly. Moreover,similar configurations for seam 106 may result when non-woven textile100 is joined with other elements, such as textile 130 or sheet 140.

As another example of the manner in which non-woven textile 100 may bejoined to another element, FIGS. 30 and 31 depict a pair of elements ofnon-woven textile 100 that are joined to form a seam 107. In thisconfiguration, an edge area of one non-woven textile 100 overlaps and isjoined with an edge of the other non-woven textile 100 at seam 107.Although a heatbond is utilized to join the pair of elements ofnon-woven textile 100 to each other, stitching or adhesive bonding mayalso be utilized to reinforce seam 107. Moreover, a single non-woventextile 100 may also be joined with other types of elements, includingtextile 130 and sheet 140, to form a similar seam 107.

A general manufacturing process for forming seam 107 will now bediscussed with reference to FIGS. 32A-32C. Initially, the pair ofelements of non-woven textile 100 are positioned in an overlappingconfiguration between first seam-forming die 117 and second seam-formingdie 118, as depicted in FIG. 32A. Seam-forming dies 117 and 118 thentranslate or otherwise move toward each other in order to compress orinduce contact between edge areas of the pair of non-woven textileelements 100, as depicted in FIG. 32B. In order to form the heatbond andjoin the edge areas of the elements of non-woven textile 100,seam-forming dies 117 and 118 apply heat to the edge areas. That is,seam-forming dies 117 and 118 elevate the temperatures of the edge areasof the pair of elements of non-woven textile 100 to cause softening ormelting of the thermoplastic polymer material at the interface betweenthe edge areas. Upon separating seam-forming dies 117 and 118, asdepicted in FIG. 32C, seam 107 is formed between the edge areas of thepair of elements of non-woven textile 100.

Although the general process discussed above may be utilized to formseam 107, other methods may also be utilized. Rather than heating theedge areas of elements of non-woven textile 100 through conduction,other methods that include radio frequency heating, chemical heating, orradiant heating may be utilized. In some processes, stitching oradhesives may also be utilized between the pair of elements of non-woventextile 100 to supplement the heatbond. As an alternate method, the pairof elements of non-woven textile 100 may be placed upon a surface, suchas second plate 112, and heated roller 119 may form seam 107, asdepicted in FIG. 33. Referring to FIG. 31, filaments 103 are depicted asremaining in the filamentous configuration in the area of seam 107, butmay be melted into a non-filamentous configuration or may take theintermediate configuration. Accordingly, although filaments 103 in thearea of seam 107 are generally fused to a greater degree than filaments103 in other areas of non-woven textile 100, the degree of fusing mayvary significantly.

First surfaces 101 of the pair of elements of non-woven textile 100 aredepicted as being co-planar or flush with each other in FIGS. 30 and 31.Similarly, second surfaces 102 of the pair of elements of non-woventextile 100 are also depicted as being coplanar or flush with eachother. Depending upon the temperature and pressure used to form seam107, the configuration of seam 107 may vary to include a variety ofother configurations. Referring to FIG. 34A, surfaces 101 and 102 bowinward at seam 107, and the thermoplastic polymer material is depictedas having a non-filamentous configuration. Surfaces 101 and 102 angleinward more-abruptly in FIG. 34B, which may be caused from pressureexerted by seam-forming dies 117 and 118. As another configuration, FIG.34C depicts the pair of elements of non-woven textile 100 as beingjoined at 107 in a non-coplanar configuration. Accordingly, theconfiguration of the pair of elements of non-woven textile 100 at seam107 may vary significantly. Moreover, similar configurations for seam107 may result when non-woven textile 100 is joined with other elements,such as textile 130 or sheet 140.

VIII—GENERAL PRODUCT CONFIGURATIONS

Non-woven textile 100, multiple elements of non-woven textile 100, orvarious composite element configurations may be utilized in articles ofapparel (e.g., shirts, jackets and other outerwear, pants, footwear),containers, and upholstery for furniture. Various configurations ofnon-woven textile 100 may also be utilized in bed coverings, tablecoverings, towels, flags, tents, sails, and parachutes, as well asindustrial purposes that include automotive and aerospace applications,filter materials, medical textiles, geotextiles, agrotextiles, andindustrial apparel. Accordingly, non-woven textile 100 may be utilizedin a variety of products for both personal and industrial purposes.

Although non-woven textile 100 may be utilized in a variety of products,the following discussion provides examples of articles of apparel thatincorporate non-woven textile 100. That is, the following discussiondemonstrates various ways in which non-woven textile 100 may beincorporated into a shirt 200, a pair of pants 300, and an article offootwear 400. Moreover, examples of various configurations of shirt 200,pants 300, and footwear 400 are provided in order to demonstrate variousconcepts associated with utilizing non-woven textile 100 in products.Accordingly, while the concepts outlined below are specifically appliedto various articles of apparel, the concepts may be applied to a varietyof other products.

IX—SHIRT CONFIGURATIONS

Various configurations of shirt 200 are depicted in FIGS. 35A-35H asincluding a torso region 201 and a pair of arm regions 202 that extendoutward from torso region 201. Torso region 201 corresponds with a torsoof a wearer and covers at least a portion of the torso when worn. Anupper area of torso region 201 defines a neck opening 203 through whichthe neck and head of the wearer protrude when shirt 200 is worn.Similarly, a lower area of torso region 201 defines a waist opening 204through which the waist or pelvic area of the wearer protrudes whenshirt 200 is worn. Arm regions 202 respectively correspond with a rightarm and a left arm of the wearer and cover at least a portion of theright arm and the left arm when shirt 200 is worn. Each of arm regions202 define an arm opening 205 through which the hands, wrists, or armsof the wearer protrude when shirt 200 is worn. Shirt 200 has theconfiguration of a shirt-type garment, particularly a long-sleevedshirt. In general, shirt-type garments cover a portion of a torso of thewearer and may extend over arms of the wearer. In further examples,apparel having the general structure of shirt 200 may have theconfiguration of other shirt-type garments, including short-sleevedshirts, tank tops, undershirts, jackets, or coats.

A first configuration of shirt 200 is depicted in FIGS. 35A and 36A. Amajority of shirt 200 is formed from non-woven textile 100. Moreparticularly, torso region 201 and each of arm regions 202 are primarilyformed from non-woven textile 100. Although shirt 200 may be formed froma single element of non-woven textile 100, shirt 200 is generally formedfrom multiple joined elements of non-woven textile 100. As depicted, forexample, at least a front area of torso region 201 is formed one elementof non-woven textile 100, and each of arm regions 202 are formed fromdifferent elements of non-woven textile 100. A pair of seams 206 extendsbetween torso region 201 and arm regions 202 in order to join thevarious elements of non-woven textile 100 together. In general, seams206 define regions where edge areas of the elements of non-woven textile100 are heatbonded with each other. Referring to FIG. 36A, one of seams206 is depicted as having the general configuration of seam 106, but mayalso have the configuration of seam 107 or another type of seam.Stitching and adhesive bonding may also be utilized to form orsupplement seams 206.

A second configuration of shirt 200 is depicted in FIGS. 35B and 36B. Aswith the configuration of FIG. 35A, a majority of shirt 200 is formedfrom non-woven textile 100. In order to impart different properties tospecific areas of shirt 200, various fused regions 104 are formed innon-woven textile 100. More particularly, fused regions 104 are formedaround neck opening 203, waist opening 204, and each of arm openings205. Given that each of openings 203-205 may be stretched as shirt 200is put on an individual and taken off the individual, fused regions 104are located around openings 203-205 in order to impart greaterstretch-resistance to these areas. Filaments 103 in fused regions 104 ofshirt 200 are generally fused to a greater degree than filaments 103 inother areas of shirt 200 and may exhibit a non-filamentousconfiguration, as depicted in FIG. 36B. Filaments 103 in fused regions104 of shirt 200 may also exhibit a filamentous configuration or theintermediate configuration. In addition to providing greaterstretch-resistance, fused regions 104 impart enhanced durability to theareas around openings 203-205.

A third configuration of shirt 200 is depicted in FIGS. 35C and 36C asincluding further fused regions 104. Given that elbow areas of shirt 200may be subjected to relatively high abrasion as shirt 200 is worn, someof fused regions 104 may be located in the elbow areas to impart greaterdurability. Also, backpack straps that extend over shoulder areas ofshirt 200 may abrade and stretch the shoulder areas. Additional fusedregions 200 are, therefore, located in the shoulder areas of shirt 200to impart both durability and stretch-resistance. The areas of non-woventextile 100 that are located in the shoulder areas and around seams 206effectively form both seams 206 and the fused regions 104 in theshoulder areas, as depicted in FIG. 36C. Two separate processes may beutilized to form these areas. That is, a first heatbonding process mayform seams 206, and a second heating process may form the fused regions104 in the shoulder areas. As an alternative, however, seams 206 and thefused regions 104 in the shoulder areas may be formed through a singleheatbonding/heating process.

Although the size of fused regions 104 in shirt 200 may varysignificantly, some of fused regions 104 generally have a continuousarea of at least one square centimeter. As noted above, variousembossing or calendaring processes may be utilized during themanufacturing process for non-woven textile 100. Some embossing orcalendaring processes may form a plurality of relatively small areas(i.e., one to ten square millimeters) where filaments 103 are somewhatfused to each other. In contrast with the areas formed by embossing orcalendaring, some of fused regions 104 have a continuous area of atleast one square centimeter. As utilized herein, “continuous area” orvariants thereof is defined as a relatively unbroken or uninterruptedregion. As examples, and with reference to FIG. 35C, the fused region104 around neck opening 203 individually forms a continuous area, eachof the fused regions 104 in the elbow areas of shirt 200 individuallyform a continuous area, and each of the fused regions 104 in theshoulder areas of shirt 200 individually form a continuous area. All offused regions 104 (i.e., around neck openings 203-205 and in theshoulder and elbow areas) are not collectively one continuous areabecause portions of non-woven textile 100 without significant fusingextend between these fused regions 104.

A fourth configuration of shirt 200 is depicted in FIGS. 35D and 36D.Referring to FIGS. 35B and 36B, fused regions 104 are utilized toprovide stretch-resistance to the areas around openings 203-205. Anotherstructure that may be utilized to provide stretch-resistance, as well asa different aesthetic, involves folding non-woven textile 100 andheatbonding or otherwise securing non-woven textile 100 to itself atvarious bond areas 207, as generally depicted in FIG. 36D. Although thisstructure may be utilized for any of openings 203-205, bond areas 207where textile 100 is heatbonded to itself are depicted as extendingaround waist opening 204 and arm openings 205.

A fifth configuration of shirt 200 is depicted in FIGS. 35E and 36E.Whereas the configurations of shirt 200 depicted in FIGS. 35A-35D areprimarily formed from non-woven textile 100, arm regions 202 in thisconfiguration of shirt 200 are formed from textile 130, which is amechanically-manipulated textile. As discussed above, seams having theconfiguration of seams 106 and 107 may join non-woven textile 100 with avariety of other materials, including textile 130. Seams 206 join,therefore, non-woven textile from torso region 201 with elements oftextile 130 from arm regions 202. Utilizing various types of textilematerials within shirt 200 may, for example, enhance the comfort,durability, or aesthetic qualities of shirt 200. Although arm regions202 are depicted as being formed from textile 130, other areas mayadditionally or alternatively be formed form textile 130 or othermaterials. For example, a lower portion of torso region 201 may beformed from textile 130, only an area around neck opening 203 may beformed from textile 130, or the configuration of FIG. 35E may bereversed such that torso region 201 is formed from textile 130 and eachof arm regions 202 are formed from non-woven textile 100. Althoughtextile 130 is utilized as an example, elements formed from thematerials of sheet 140 or foam layer 150 may also be incorporated intoshirt 200 and joined with non-woven textile 100. Accordingly, an articleof apparel, such as shirt 200, may incorporate both non-woven textile100 and various other textiles or materials. Various fused regions 104are also formed in the non-woven textile 100 of torso region 201 inorder to impart different properties to specific areas of shirt 200 thatincorporate non-woven textile 100.

A sixth configuration of shirt 200 is depicted in FIGS. 35F and 36F, inwhich a majority of shirt 200 is formed from a composite element ofnon-woven textile 100 and textile 130. More particularly, the materialforming shirt 200 has a layered structure including an outer layer ofnon-woven textile 100 and an inner layer of textile 130. The combinationof non-woven textile 100 and textile 130 may impart some advantages overeither of non-woven textile 100 and textile 130 alone. For example,textile 130 may exhibit one-directional stretch that impartsone-directional stretch to the composite element. Textile 130 may alsobe positioned to contact the skin of an individual wearing shirt 200,and the materials selected for textile 130 and the structure of textile130 may impart more comfort than non-woven textile 100 alone. As anadditional matter, the presence of non-woven textile 100 permitselements to be joined through heatbonding. Referring to FIG. 36F,surfaces of the composite material that include non-woven textile 100are heatbonded to each other to join elements from torso region 201 andone of arm regions 202. Various fused regions 104 are also formed inregions 201 and 202 in order to impart different properties to specificareas of shirt 200.

A seventh configuration of shirt 200 is depicted in FIGS. 35G and 36G.In order to provide protection to a wearer, various sheets 140 and foamlayers 150 are heatbonded to an interior surface of non-woven textile100. More particularly, two sheets 140 are located in the shoulder areasof shirt 200, two sheets 140 are located in arm regions 202, and twofoam layers 150 are located on sides of torso region 201. Various fusedregions 104 are also formed in non-woven textile 100. More particularly,a pair of fused regions 104 extend around the areas where foam layers150 are located in torso region 201, and a pair of fused regions 104extend over the areas where sheets 140 are located in arm regions 202.These fused regions 104 may be utilized to reinforce or addstretch-resistance to areas surrounding foam layers 150 or providegreater durability to areas over sheets 140, for example.

An eighth configuration of shirt 200 is depicted in FIGS. 35H and 36H.In addition to various fused regions 104 that are formed in non-woventextile 100, a plurality of strands 160 are also embedded withinnon-woven textile 100 to, for example, impart stretch-resistance oradditional strength to specific areas of shirt 200. More particularly,seven strands 160 radiate outward and downward from a point in an upperportion of torso region 201, two strands 160 extend in parallel alongeach of arm regions 202, and at least one strand 160 extends acrossseams 206 in shoulder areas of shirt 200. Some of strands 160 extendthrough various fused regions 104 that may impart additionalstretch-resistance or durability, for example, to the areas surroundingstrands 160. In torso region 201, each of strands 160 pass through oneof fused regions 104, while two of strands 160 extend along a pair offused regions 104. In the shoulder areas of shirt 200, a pair of strands160 are located entirely within fused regions 104. Accordingly, strands160 may be utilized alone or coupled with fused regions 104.

Based upon the above discussion, non-woven textile 100 may be utilizedin an article of apparel, such as shirt 200. In some configurations,seams 206 having the configuration of either of seams 106 or 107 may beused to join textile elements, including elements of non-woven textile100. In order to impart different properties to areas of shirt 200,various fused regions 104 may be formed, different types of textiles maybe incorporated into shirt 200, and composite elements may be formed byjoining one or more of textile 130, sheet 140, foam layer 150, strands160, or various other components to non-woven textile 100. By formingfused regions 104 in non-woven textile 100 and combining non-woventextile 100 with other components to form composite elements, variousproperties and combinations of properties may be imparted to differentareas of shirt 200. That is, the various concepts disclosed herein maybe utilized individually or in combination to engineer the properties ofshirt 200 and tailor shirt 200 to a specific purpose. Given thatnon-woven textile 100 incorporates a thermoplastic polymer material,seams 206 and the composite elements may be formed through heatbonding.

X—PANTS CONFIGURATIONS

Various configurations of pants 300 are depicted in FIGS. 37A-37C asincluding a pelvic region 301 and a pair of leg regions 302 that extenddownward from pelvic region 301. Pelvic region 301 corresponds with alower torso and pelvis bone of a wearer and covers at least a portion ofthe lower torso when worn. An upper area of pelvic region 301 defines awaist opening 303 through which the torso extends when pants 300 areworn. Leg regions 302 respectively correspond with a right leg and aleft leg of the wearer and cover at least a portion of the right leg andthe left leg when pants 300 are worn. Each of leg regions 302 define anankle opening 304 through which the ankle and feet of the wearerprotrude when pants 300 are worn. Pants 300 have the configuration of apants-type garment, particularly a pair of athletic pants. In general,pants-type garments cover the lower torso of the wearer and may extendover legs of the wearer. In further examples, apparel having the generalstructure of pants 300 may have the configuration of other pants-typegarments, including shorts, jeans, briefs, swimsuits, and undergarments.

A first configuration of pants 300 is depicted in FIG. 37A. A majorityof pants 300 is formed from non-woven textile 100. More particularly,pelvic region 301 and each of leg regions 302 are primarily formed fromnon-woven textile 100. Although pants 300 may be formed from a singleelement of non-woven textile 100, pants 300 is generally formed frommultiple joined elements of non-woven textile 100. Although notdepicted, seams similar to seams 106, 107, or 206 may be utilized tojoin the various elements of non-woven textile 100 together. Stitchingand adhesive bonding may also be utilized to form or supplement theseams.

A pocket 305 is formed in pants 300 and may be utilized to hold orotherwise contain relatively small objects (e.g., keys, wallet,identification card, mobile phone, portable music player). Twooverlapping layers of non-woven textile 100 are utilized to form pocket305, as depicted in FIG. 38. More particularly, a bond area 306 isutilized to heatbond the layers of non-woven textile 100 to each other.A central area of one of the layers of non-woven textile 100 remainsunbonded, however, to form the areas within pocket 305 for containingthe objects. A pocket similar to pocket 305 may also be formed in otherproducts and articles of apparel, including shirt 200.

A second configuration of pants 300 is depicted in FIG. 37B. As with theconfiguration of FIG. 37A, a majority of pants 300 is formed fromnon-woven textile 100. In order to impart different properties tospecific areas of pants 300, various fused regions 104 are formed innon-woven textile 100. More particularly, fused regions 104 are formedaround waist opening 303 and each of leg openings 304. Another fusedregion 104 is formed at an opening for pocket 305. Given that each ofopenings 303 and 304, as well as the opening to pocket 305, may bestretched, fused regions 104 may be utilized to impart greaterstretch-resistance to these areas. That is, filaments 103 in fusedregions 104 of pants 300 are generally fused to a greater degree thanfilaments 103 in other areas of pants 300 and may have any of thefilamentous, non-filamentous, or intermediate configurations discussedabove. In addition to providing greater stretch-resistance, fusedregions 104 impart enhanced durability. Given that knee areas of pants300 may be subjected to relatively high abrasion as pants 300 are worn,additional fused regions 104 may be located in the knee areas to impartgreater durability.

A third configuration of pants 300 is depicted in FIG. 37C. As withshirt 200, fused regions 104, textile 130, sheet 140, foam layer 150,and strands 160 may be utilized to impart properties to various areas ofpants 300. In leg regions 302, for example, textile 130 is heatbonded toan interior surface of non-woven textile 100. A pair of sheets 140 areheatbonded to pants 300 in side areas of pelvic region 301, and portionsof the fused region 104 around waist opening 303 extend under sheets140. A pair of foam layers 150 are also located in the knee areas ofpants 300, and strands 160 that extend along leg regions 302 extendunder foam layers 150 (e.g., between non-woven textile 100 and foamlayers 150). End areas of strands 160 also extend into fused regions 104in lower areas of leg regions 302. Accordingly, fused regions 104,textile 130, sheet 140, foam layer 150, and strands 160 may be utilizedor combined in a variety of ways to impart properties to differentvarious areas of pants 300. Whereas various elements of sheet 140 andfoam layer 150 are heatbonded with an interior surface of shirt 200 inFIG. 35G, various elements of sheet 140 and foam layer 150 areheatbonded with an exterior surface of pants 300 in FIG. 37C. Dependingupon various structural and aesthetic factors, composite elements andapparel including the composite elements may be formed with components(e.g., textile 130, sheet 140, foam layer 150, strands 160) located onan exterior or an interior of non-woven textile 100.

Based upon the above discussion, non-woven textile 100 may be utilizedin an article of apparel, such as pants 300. Seams of various types maybe used to join textile elements, including elements of non-woventextile 100. In order to impart different properties to areas of pants300, various fused regions 104 may be formed, different types oftextiles may be incorporated into shirt 200, and composite elements maybe formed by joining one or more of textile 130, sheet 140, foam layer150, strands 160, or various other components to non-woven textile 100.By forming fused regions 104 in non-woven textile 100 and combiningnon-woven textile 100 with other components to form composite elements,various properties and combinations of properties may be imparted todifferent areas of pants 300. That is, the various concepts disclosedherein may be utilized individually or in combination to engineer theproperties of pants 300 and tailor pants 300 to a specific purpose.Given that non-woven textile 100 incorporates a thermoplastic polymermaterial, the seams and composite elements may be formed throughheatbonding.

XI—FOOTWEAR CONFIGURATIONS

Various configurations of footwear 400 are depicted in FIGS. 39A-39G asincluding a sole structure 410 and an upper 420. Sole structure 410 issecured to upper 420 and extends between the foot of a wearer and theground when footwear 400 is placed upon the foot. In addition toproviding traction, sole structure 410 may attenuate ground reactionforces when compressed between the foot and the ground during walking,running, or other ambulatory activities. As depicted, sole structure 410includes a fluid-filled chamber 411, a reinforcing structure 412 that isbonded to and extends around an exterior of chamber 411, and an outsole413 that is secured to a lower surface of chamber 411, which is similarto a sole structure that is disclosed in U.S. Pat. No. 7,086,179 toDojan, et al., which is incorporated by reference herein. Theconfiguration of sole structure 410 may vary significantly to include avariety of other conventional or nonconventional structures. As anexample, sole structure 410 may incorporate a polymer foam element inplace of chamber 411 and reinforcing structure 412, and the polymer foamelement may at least partially encapsulate a fluid-filled chamber, asdisclosed in either of U.S. Pat. Nos. 7,000,335 to Swigart, et al. and7,386,946 to Goodwin, which are incorporated by reference herein. Asanother example, sole structure 410 may incorporate a fluid-filledchamber with an internal foam tensile member, as disclosed in U.S. Pat.No. 7,131,218 to Schindler, which is incorporated by reference herein.Accordingly, sole structure 410 may have a variety of configurations.

Upper 420 defines a void within footwear 400 for receiving and securingthe foot relative to sole structure 410. More particularly, upper 420 isstructured to extend along a lateral side of the foot, along a medialside of the foot, over the foot, and under the foot, such that the voidwithin upper 420 is shaped to accommodate the foot. Access to the voidis provided by an ankle opening 421 located in at least a heel region offootwear 400. A lace 422 extends through various lace apertures 423 inupper 420 and permits the wearer to modify dimensions of upper 420 toaccommodate the proportions of the foot. Lace 422 also permits thewearer to loosen upper 420 to facilitate entry and removal of the footfrom the void. Although not depicted, upper 420 may include a tonguethat extends under lace 422 to enhance the comfort or adjustability offootwear 400.

A first configuration of footwear 400 is depicted in FIGS. 39A and 40A.Portions of upper 420 that extend along sides of the foot, over thefoot, and under the foot may be formed from various elements ofnon-woven textile 100. Although not depicted, seams similar to seams 106and 107 may be used to join the elements of non-woven textile 100. Inmany articles of footwear, stitching or adhesives are utilized to jointhe upper and sole structure. Sole structure 410, however, may be atleast partially formed from a thermoplastic polymer material. Moreparticularly, chamber 411 and reinforcing structure 412 may be at leastpartially formed from a thermoplastic polymer material that joins toupper 420 with a heatbond. That is, a heatbonding process may beutilized to join sole structure 410 and upper 420. In someconfigurations, stitching or adhesives may be utilized to join solestructure 410 and upper 420, or the heatbond may be supplemented withstitching or adhesives.

A relatively large percentage of footwear 400 may be formed fromthermoplastic polymer materials. As discussed above, non-woven textile100, chamber 411, and reinforcing structure 412 may be at leastpartially formed from thermoplastic polymer materials. Although lace 422is not generally joined to upper 420 through bonding or stitching, lace422 may also be formed from a thermoplastic polymer material. Similarly,outsole 413 may also be formed from a thermoplastic polymer material.Depending upon the number of elements of footwear 400 that incorporatethermoplastic polymer materials or are entirely formed fromthermoplastic polymer materials, the percentage by mass of footwear 400that is formed from the thermoplastic polymer materials may range fromthirty percent to one-hundred percent. In some configurations, at leastsixty percent of a combined mass of upper 420 and sole structure 410 maybe from the thermoplastic polymer material of non-woven textile 100 andthermoplastic polymer materials of at least one of (a) other elements ofupper 420 (i.e., lace 422) and (b) the elements of sole structure 410(i.e., chamber 411, reinforcing structure 412, outsole 413). In furtherconfigurations, at least eighty percent or even at least ninety percentof a combined mass of upper 420 and sole structure 410 may be from thethermoplastic polymer material of non-woven textile 100 andthermoplastic polymer materials of at least one of (a) other elements ofupper 420 and (b) the elements of sole structure 410. Accordingly, amajority or even all of footwear 400 may be formed from one or morethermoplastic polymer materials.

A second configuration of footwear 400 is depicted in FIGS. 39B and 40B,in which three generally linear fused regions 104 extend from a heelarea to a forefoot area of footwear 400. As discussed in detail above,the thermoplastic polymer material forming filaments 103 of non-woventextile 100 is fused to a greater degree in fused regions 104 than inother areas of non-woven textile 100. The thermoplastic polymer materialfrom filaments 103 may also be fused to form a non-filamentous portionof non-woven textile 100. The three fused regions 104 form, therefore,areas where filaments 103 are fused to a greater degree than in otherareas of upper 420. Fused regions 104 have generally greaterstretch-resistance than other areas of non-woven textile 100. Given thatfused regions 104 extend longitudinally between the heel area and theforefoot area of footwear 400, fused regions 104 may reduce the amountof longitudinal stretch in footwear 400. That is, fused regions 104 mayimpart greater stretch-resistance to footwear 400 in the directionbetween the heel area and the forefoot area. Fused regions 104 may alsoincrease the durability of upper 420 and decrease the permeability ofupper 420.

A third configuration of footwear 400 is depicted in FIGS. 39C and 40C.Various fused regions 104 are formed in non-woven textile 100. One offused regions 104 extends around and is proximal to ankle opening 421,which may add greater stretch-resistance to the area around ankleopening 421 and assists with securely-retaining the foot within upper420. Another fused region 104 is located in the heel region and extendsaround a rear area of the footwear to form a heel counter that resistsmovement of the heel within upper 420. A further fused region 104 islocated in the forefoot area and adjacent to the sole structure, whichadds greater durability to the forefoot area. More particularly, theforefoot area of upper 420 may experience greater abrasive-wear thanother portions of upper 420, and the addition to fused region 104 in theforefoot area may enhance the abrasion-resistance of footwear 400 in theforefoot area. Additional fused regions 104 extend around some of laceapertures 423, which may enhance the durability and stretch-resistanceof areas that receive lace 422. Fused regions 104 also extend downwardfrom an area that is proximal to lace apertures 423 to an area that isproximal to sole structure 410 in order to enhance thestretch-resistance along the sides of footwear 400. More particularly,tension in lace 422 may place tension in the sides of upper 420. Byforming fused regions 104 that extend downward along the sides of upper420, the stretch in upper 420 may be reduced.

The size of fused regions 104 in footwear 400 may vary significantly,but fused regions 104 generally have a continuous area of at least onesquare centimeter. As noted above, various embossing or calendaringprocesses may be utilized during the manufacturing process for non-woventextile 100. Some embossing or calendaring processes may form aplurality of relatively small areas (i.e., one to ten squaremillimeters) where filaments 103 are somewhat fused to each other. Incontrast with the areas formed by embossing or calendaring, fusedregions 104 have a continuous area, as defined above, of at least onesquare centimeter.

Although a majority of upper 420 may be formed from a single layer ofnon-woven textile 100, multiple layers may also be utilized. Referringto FIG. 40C, upper 420 includes an intermediate foam layer 150 betweentwo layers of non-woven textile 100. An advantage to this configurationis that foam layer imparts additional cushioning to the sides of upper420, thereby protecting and imparting greater comfort to the foot. Ingeneral, the portions of upper 420 that incorporate foam layer 150 maybe formed to have the general configuration of the composite elementdiscussed above relative to FIGS. 19 and 20. Moreover, a heatbondingprocess similar to the process discussed above relative to FIGS. 12A-12Cmay be utilized to form the portions of upper 420 that incorporate foamlayer 150. As an alternative to foam layer 150, textile 130 or sheet 140may also be heatbonded to non-woven textile 100 in footwear 400.Accordingly, incorporating various composite elements into footwear 400may impart a layered configuration with different properties.

A fourth configuration of footwear 400 is depicted in FIGS. 39D and 40D,in which various strands 160 are embedded within non-woven textile 100.In comparison with the thermoplastic polymer material forming non-woventextile 100, many of the materials noted above for strands 160 exhibitgreater tensile strength and stretch-resistance. That is, strands 160may be stronger than non-woven textile 100 and may exhibit less stretchthan non-woven textile 100 when subjected to a tensile force. Whenutilized within footwear 400, therefore, strands 160 may be utilized toimpart greater strength and stretch-resistance than non-woven textile100.

Strands 160 are embedded within non-woven textile 100 or otherwisebonded to non-woven textile 100. Many of strands 160 extend in adirection that is substantially parallel to a surface of non-woventextile 100 for a distance of at least five centimeters. An advantage toforming at least some of strands 160 to extend through the distance ofat least five centimeters is that tensile forces upon one area offootwear 400 may be transferred along strands 160 to another area offootwear 400. One group of strands 160 extends from the heel area to theforefoot area of footwear 400 to increase strength and reduce the amountof longitudinal stretch in footwear 400. That is, these strands 160 mayimpart greater strength and stretch-resistance to footwear 400 in thedirection between the heel area and the forefoot area. Another group ofstrands 160 extends downward from an area that is proximal to laceapertures 423 to an area that is proximal to sole structure 410 in orderto enhance the strength and stretch-resistance along the sides offootwear 400. More particularly, tension in lace 422 may place tensionin the sides of upper 420. By positioning strands 160 to extend downwardalong the sides of upper 420, the stretch in upper 420 may be reduced,while increasing the strength. A further group of strands 160 is alsolocated in the heel region to effectively form a heel counter thatenhances the stability of footwear 400. Additional details concerningfootwear having a configuration that includes strands similar to strands160 are disclosed in U.S. Patent Application Publication US2007/0271821to Meschter, which is incorporated by reference herein.

A fifth configuration of footwear 400 is depicted in FIG. 39E. Incontrast with the configuration of FIGS. 39D and 40D, various fusedregions 104 are formed in non-woven textile 100. More particularly,fused regions 104 are located in the areas of the groups of strands 160that (a) extend downward from an area that is proximal to lace apertures423 to an area that is proximal to sole structure 410 and (b) arelocated in the heel region. At least a portion of strands 160 extendthrough the fused regions 104, which imparts additionalstretch-resistance and greater durability to the areas of upper 420 thatincorporate strands 160, thereby providing greater protection to strands160. Fused regions 104 may have a continuous area of at least one squarecentimeter, and the thermoplastic polymer material from filaments 103within fused regions 104 may be either, filamentous, non-filamentous, ora combination of filamentous and non-filamentous.

A sixth configuration of footwear 400 is depicted in FIG. 39F. Threefused regions 104 in the side of footwear 400 have the shapes of theletters “A,” “B,” and “C.” As discussed above, fused regions 104 may beutilized to modify various properties of non-woven textile 100,including the properties of permeability, durability, andstretch-resistance. In general, various aesthetic properties may also bemodified by forming fused regions 104, including the transparency andthe darkness of a color of non-woven textile 100. That is, the color offused regions 104 may be darker than the color of other portions ofnon-woven textile 100. Utilizing this change in aesthetic properties,fused regions 104 may be utilized to form indicia in areas of footwear400. That is, fused regions 104 may be utilized to form a name or logoof a team or company, the name or initials of an individual, or anesthetic pattern, drawing, or element in non-woven textile 100.Similarly, fused regions 104 may be utilized to form indicia in shirt200, pants 300, or any other product incorporating non-woven textile100.

Fused regions 104 may be utilized to form indicia in the side offootwear 400, as depicted in FIG. 39F, and also in shirt 200, pants 300,or a variety of other products incorporating non-woven textile 100. As arelated matter, elements of non-woven textile 100 may be heatbonded orotherwise joined to various products to form indicia. For example,elements of non-woven textile 100 having the shapes of the letters “A,”“B,” and “C” may be heatbonded to the sides of an article of footwearwhere the upper is primarily formed from synthetic leather. Given thatnon-woven textile 100 may be heatbonded to a variety of other materials,elements of non-woven textile 100 may be heatbonded to products in orderto form indicia.

Seams similar to seams 106 and 107 may be used to join the elements ofnon-woven textile 100 in any configuration of footwear 400. Referring toFIG. 39F, a pair of seams 424 extend in a generally diagonal directionthrough upper 420 to join different elements of non-woven textile 100.Although heatbonding may be utilized to form seams 424, stitching oradhesives may also be utilized. As noted above, sole structure 410 mayalso have various structures, in addition to the structure that includeschamber 411 and reinforcing structure 412. Referring again to FIG. 39F,a thermoplastic polymer foam material 425 is utilized in place ofchamber 411 and reinforcing structure 412, and upper 420 may beheatbonded to foam material 425 to join sole structure 410 to upper 420.Heatbonds may also be utilized when a thermoset polymer foam material isutilized within sole structure 410.

A seventh configuration of footwear 400 is depicted in FIG. 39G, whereinnon-woven textile 100 is utilized to form a pair of straps 426 thatreplace or supplement lace 422. In general, straps 426 permit the wearerto modify dimensions of upper 420 to accommodate the proportions of thefoot. Straps 426 also permit the wearer to loosen upper 420 tofacilitate entry and removal of the foot from the void. One end ofstraps 426 may be permanently secured to upper 420, whereas a remainderof straps 426 may be joined with a hook-and-loop fastener, for example.This configuration allows straps to be adjusted by the wearer. Asdiscussed above, non-woven textile 100 may stretch and return to anoriginal configuration after being stretched. Utilizing this property,the wearer may stretch straps 426 to impart tension, thereby tighteningupper 420 around the foot. By lifting straps, the tension may bereleased to allow entry and removal of the foot.

In addition to forming the portion of upper 420 that extends along andaround the foot to form the void for receiving the foot, non-woventextile 100 may also form structural elements of footwear 400. As anexample, a lace loop 427 is depicted in FIG. 41. Lace loop 427 may beincorporated into upper 420 as a replacement or alternative for one ormore of the various lace apertures 423. Whereas lace apertures 423 areopenings through upper 420 that receive lace 422, lace loop 427 is afolded or overlapped area of non-woven textile 100 that defines achannel through which lace 422 extends. In forming lace loop 427,non-woven textile 100 is heatbonded to itself at a bond area 428 to formthe channel.

Based upon the above discussion, non-woven textile 100 may be utilizedin apparel having the configuration of an article of footwear, such asfootwear 400. In order to impart different properties to areas offootwear 400, various fused regions 104 may be formed, different typesof textiles may be incorporated into footwear 400, and compositeelements may be formed by joining one or more of textile 130, sheet 140,foam layer 150, strands 160, or various other components to non-woventextile 100. Given that non-woven textile 100 incorporates athermoplastic polymer material, a heatbonding process may be utilized tojoin upper 420 to sole structure 410.

XII—FORMING, TEXTURING, AND COLORING THE NON-WOVEN TEXTILE

The configuration of non-woven textile 100 depicted in FIG. 1 has agenerally planar configuration. Non-woven textile 100 may also exhibit avariety of three-dimensional configurations. As an example, non-woventextile 100 is depicted as having a wavy or undulating configuration inFIG. 42A. A similar configuration with squared waves is depicted in FIG.42B. As another example, non-woven textile may have waves that extend intwo directions to impart an egg crate configuration, as depicted in FIG.42C. Accordingly, non-woven textile 100 may be formed to have a varietyof non-planar or three-dimensional configurations.

A variety of processes may be utilized to form a three-dimensionalconfiguration in non-woven textile 100. Referring to FIGS. 43A-43C, anexample of a method is depicted as involving first plate 111 and secondplate 112, which each have surfaces that correspond with the resultingthree-dimensional aspects of non-woven textile 100. Initially, non-woventextile 100 is located between plates 111 and 112, as depicted in FIG.43A. Plates 111 and 112 then translate or otherwise move toward eachother in order to contact and compress non-woven textile 100, asdepicted in FIG. 43B. In order to form the three-dimensionalconfiguration in non-woven textile 100, heat from one or both of plates111 and 112 is applied to non-woven textile 100 so as to soften or meltthe thermoplastic polymer material within filaments 103. Upon separatingplates 111 and 112, as depicted in FIG. 43C, non-woven textile 100exhibits the three-dimensional configuration from the surfaces of plates111 and 112. Although heat may be applied through conduction, radiofrequency or radiant heating may also be used. As another example of aprocess that may be utilized to form a three-dimensional configurationin non-woven textile 100, filaments 103 may be directly deposited upon athree-dimensional surface in the process for manufacturing non-woventextile 100.

In addition to forming non-woven textile 100 to have three-dimensionalaspects, a texture may be imparted to one or both of surfaces 101 and102. Referring to FIG. 44A, non-woven textile 100 has a configurationwherein first surface 101 is textured to include a plurality ofwave-like features. Another configuration is depicted in FIG. 44B,wherein first surface 101 is textured to include a plurality of x-shapedfeatures. Textures may also be utilized to convey information, as in theseries of alpha-numeric characters that are formed in first surface 101in FIG. 44C. Additionally, textures may be utilized to impart theappearance of other materials, such as the synthetic leather texture inFIG. 44D.

A variety of processes may be utilized to impart a texture to non-woventextile 100. Referring to FIGS. 45A-45C, an example of a method isdepicted as involving first plate 111 and second plate 112, which eachhave textured surfaces. Initially, non-woven textile 100 is locatedbetween plates 111 and 112, as depicted in FIG. 45A. Plates 111 and 112then translate or otherwise move toward each other in order to contactand compress non-woven textile 100, as depicted in FIG. 45B. In order toimpart the textured configuration in non-woven textile 100, heat fromone or both of plates 111 and 112 is applied to non-woven textile 100 soas to soften or melt the thermoplastic polymer material within filaments103. Upon separating plates 111 and 112, as depicted in FIG. 45C,non-woven textile 100 exhibits the texture from the surfaces of plates111 and 112. Although heat may be applied through conduction, radiofrequency or radiant heating may also be used. As another example of aprocess that may be utilized to form textured surfaces in non-woventextile 100, a textured release paper may be placed adjacent tonon-woven textile 100. Upon compressing and heating, the texture fromthe release paper may be transferred to non-woven textile 100.

Depending upon the type of polymer material utilized for non-woventextile 100, a variety of coloring processes may be utilized to impartcolor to non-woven textile 100. Digital printing, for example, may beutilized to deposit dye or a colorant onto either if surfaces 101 and102 to form indicia, graphics, logos, or other aesthetic features.Instructions, size identifiers, or other information may also be printedonto non-woven textile 100. Moreover, coloring processes may be utilizedbefore or after non-woven textile 100 is incorporated into a product.Other coloring processes, including screen printing and laser printing,may be used to impart colors or change the overall color of portions ofnon-woven textile 100.

Based upon the above discussion, three-dimensional, textured, andcolored configurations of non-woven textile 100 may be formed. Whenincorporated into products (e.g., shirt 200, pants 300, footwear 400),these features may provide both structural and aesthetic enhancements tothe products. For example, the three-dimensional configurations mayprovide enhanced impact force attenuation and greater permeability byincreasing surface area. Texturing may increase slip-resistance, as wellas providing a range of aesthetic possibilities. Moreover, coloringnon-woven textile 100 may be utilized to convey information and increasethe visibility of the products.

XIII—STITCH CONFIGURATIONS

Stitching may be utilized to join an element of non-woven textile 100 toother elements of non-woven textile 100, other textiles, or a variety ofother materials. As discussed above, stitching may be utilized alone, orin combination with heatbonding or adhesives to join non-woven textile100. Additionally, stitching, embroidery, or stitchbonding may be usedto form a composite element and provide structural or aesthetic elementsto non-woven textile 100. Referring to FIG. 46A, a thread 163 isstitched into non-woven textile 100 to form a plurality of parallellines that extend across non-woven textile 100. Whereas strands 160extend in a direction that is substantially parallel to either ofsurfaces 101 and 102, thread 163 repeatedly extends between surfaces 101and 102 (i.e., through non-wove textile 100) to form a stitchedconfiguration. Like strand 160, however, thread 163 may impartstretch-resistance and enhance the overall strength of non-woven textile100. Thread 163 may also enhance the overall aesthetics of non-woventextile 100. When incorporated into products having non-woven textile100 (e.g., shirt 200, pants 300, footwear 400), thread 163 may provideboth structural and aesthetic enhancements to the products.

Thread 163 may be stitched to provide a variety of stitchconfigurations. As an example, thread 163 has the configuration of azigzag stitch in FIG. 46B and the configuration of a chain stitch inFIG. 46C. Whereas thread 163 forms generally parallel lines of stitchesin FIGS. 46A and 46B, the stitches formed by thread 163 are non-paralleland cross each other in FIG. 46C. Thread 163 may also be embroidered toform various configurations, as depicted in FIG. 46D. Stitching may alsobe utilized to form more complicated configurations with thread 163, asdepicted in FIG. 46E. Non-woven textile 100 may also include variousfused regions 104, with the stitches formed by thread 163 extendingthrough both fused and non-fused areas of non-woven textile 100, asdepicted in FIG. 46F. Accordingly, thread 163 may be utilized to form avariety of stitch types that may impart stretch-resistance, enhancestrength, or enhance the overall aesthetics of non-woven textile 100.Moreover, fused regions 104 may also be formed in non-woven textile 100to modify other properties.

XIV—ADHESIVE TAPE

An element of tape 170 is depicted in FIGS. 47 and 48 as having theconfiguration of a composite elements that includes non-woven textile100 and an adhesive layer 171. Tape 170 may be utilized for a variety ofpurposes, including as packing tape, as painting tape, or as medical ortherapeutic tape. An advantage to utilizing tape 170 as medical ortherapeutic tape, for example, is that the permeability andstretch-resistance, among other properties, may be controlled. Withregard to permeability, when tape 170 to be adhered to the skin of anindividual (i.e., with adhesive layer 171), air and water may passthrough tape 170 to impart breathability and allow the underlying skinto be washed or otherwise cleansed. Tape 170 may also resist stretchwhen adhered to the skin of the individual to provide support forsurrounding soft tissue. Examples of suitable materials for adhesivelayer 171 include any of the conventional adhesives utilized intape-type products, including medical-grade acrylic adhesive.

A variety of structures that be utilized to impart specific degrees ofstretch-resistance to tape 170. As an example, the stretch-resistance totape 170 may be controlled though the thickness of non-woven textile 100or the materials forming filaments 103 in non-woven textile 100.Referring to FIG. 49A, fused regions 104 may also be formed in tape 170to control stretch-resistance. Strands 160 may also be incorporated intotape 170 to impart a higher level of stretch-resistance, as depicted inFIG. 49B. Additionally, some configurations of tape 170 may include bothfused regions 104 and strands 160, as depicted in FIG. 49C.

XV—RECYCLING THE NON-WOVEN TEXTILE

Filaments 103 of non-woven textile 100 include a thermoplastic polymermaterial. In some configurations of non-woven textile 100, a majority orsubstantially all of filaments 103 are formed from the thermoplasticpolymer material. Given that many configurations of shirt 200 and pants300 are primarily formed from non-woven textile 100, then a majority orsubstantially all of shirt 200 and pants 300 are formed from thethermoplastic polymer material. Similarly, a relatively large percentageof footwear 400 may also be formed from thermoplastic polymer materials.Unlike many articles of apparel, the materials of shirt 200, pants 300,and footwear 400 may be recycled following their useful lives.

Utilizing shirt 200 as an example, the thermoplastic polymer materialfrom shirt 200 may be extracted, recycled, and incorporated into anotherproduct (e.g., apparel, container, upholstery) as a non-woven textile, apolymer foam, or a polymer sheet. This process is generally shown inFIG. 50, in which shirt 200 is recycled in a recycling center 180, andthermoplastic polymer material from shirt 200 is incorporated into oneor more of another shirt 200, pants 300, or footwear 400. Moreover,given that a majority or substantially all of shirt 200 is formed fromthe thermoplastic polymer material, then a majority or substantially allof the thermoplastic polymer material may be utilized in another productfollowing recycling. Although the thermoplastic polymer material fromshirt 200 was initially utilized within non-woven textile 100, forexample, the thermoplastic polymer material from shirt 200 may besubsequently utilized in another element of non-woven textile 100,another textile that includes a thermoplastic polymer material, apolymer foam, or a polymer sheet. Pants 300, footwear 400, and otherproducts incorporating non-woven textile 100 may be recycled through asimilar process. Accordingly, an advantage of forming shirt 200, pants300, footwear 400, or other products with the various configurationsdiscussed above relates to recyclability.

XVI—CONCLUSION

Non-woven textile 100 includes a plurality of filaments 103 that are atleast partially formed from a thermoplastic polymer material. Variousfused regions 104 may be formed in non-woven textile 100 to modifyproperties that include permeability, durability, andstretch-resistance. Various components (textiles, polymer sheets, foamlayers, strands) may also be secured to or combined with non-woventextile 100 (e.g., through heatbonding) to impart additional propertiesor advantages to non-woven textile 100. Moreover, fused regions 104 andthe components may be combined to impart various configurations tonon-woven textile 100.

The invention is disclosed above and in the accompanying figures withreference to a variety of configurations. The purpose served by thedisclosure, however, is to provide an example of the various featuresand concepts related to the invention, not to limit the scope of theinvention. One skilled in the relevant art will recognize that numerousvariations and modifications may be made to the configurations describedabove without departing from the scope of the present invention, asdefined by the appended claims.

1-10. (canceled)
 11. An article of apparel comprising at least one non-woven textile element that includes a plurality of filaments at least partially formed from a thermoplastic polymer material, the non-woven textile having a first region and a second region, each of the first region and the second region having a continuous area of at least one square centimeter, and the thermoplastic polymer material from filaments of the first region being fused to form a non-filamentous portion of the non-woven textile.
 12. The article of apparel recited in claim 11, wherein the article of apparel is a shirt-type garment.
 13. The article of apparel recited in claim 12, wherein the first region is located in a shoulder area of the shirt-type garment.
 14. The article of apparel recited in claim 12, wherein the first region is located around at least one of a neck opening, an arm opening, and a waist opening of the shirt-type garment.
 15. The article of apparel recited in claim 11, wherein the article of apparel is a pants-type garment.
 16. The article of apparel recited in claim 15, wherein the first region is located in a knee area of the pants-type garment.
 17. The article of apparel recited in claim 15, wherein the first region is located around at least one of a waist opening and a leg opening of the pants-type garment.
 18. The article of apparel recited in claim 11, wherein the thermoplastic polymer filaments stretch at least one-hundred percent prior to tensile failure.
 19. The article of apparel recited in claim 11, wherein the article of apparel also includes a second textile element, an edge area of the non-woven textile element being heatbonded with an edge area of the second textile element.
 20. The article of apparel recited in claim 11, wherein the article of apparel is an article of footwear. 21-115. (canceled) 